Remove/install cylinder head cover

AR01.20-P-5014OLI

Remove/install cylinder head cover

20.05.2020

Engine

654 in model 205, 253

Modification notes

26.09.2019

Operation steps added.

Operation steps 7, 8

Shown on model 253

1

Cylinder head cover

12

Impact plate

5

Support brace

13

Pressure line

11

Noise insulation

1

Cylinder head cover

6

Bolts

8

Screw

5

Support brace

7

Bracket

1

Cylinder head cover

2

Bolts

3

Sealing rings

4

Bracket

9

Sealing beads

A

Sealant

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

General information on checking camshafts and bearing points of camshafts

AH05.20-P-1000-09SZ

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

 

Remove/install

1

Remove fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).

AR07.03-P-0004OLI

 Installation: Only install upper engine cover after the leak test.

2

Remove rail.

AR07.03-P-1010OLI

3

Remove low pressure exhaust gas recirculation actuator (Y27/7) from the exhaust gas recirculation cooler and place to one side with connected lines.

AR14.20-P-7683OLI

4

Disconnect the engine wiring harness for removing the cylinder head cover (1).

Engine 654 in model 253

AR15.18-P-1000-04OLG

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A

Engine 654 in model 205

AR15.18-P-1000-04OLI

5

Remove camshaft Hall sensor (B6/1).

AR15.10-P-1999OLI

6

Press sound insulation to the side and remove support (5).

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Screw, bracket for low-pressure exhaust gas recirculation cooler to cylinder head cover/low-pressure exhaust gas recirculation cooler/lifting lug

*BA14.20-P-1015-01Q

7

Remove pressure line (13) from the cylinder head cover (1) and place to one side.

 Bolt, holder for boost pressure sensor of low-pressure exhaust gas turbocharger to cylinder head cover

*BA07.04-P-1022-02A

8

Remove noise insulation (11).

Engine 654 in model 205, 253
with code M014 (Engine uprated)

9

Remove impact plate (12).

10

Remove NOx sensor control unit upstream of the diesel oxidation catalytic converter (N37/12) from the catalytic converter and place to one side with connected lines.

AR49.20-P-2061OLI

11

Remove screws (6), remove bracket (7) and place to one side with lines connected.

 Screw, holder to high-pressure exhaust gas recirculation valve/high-pressure exhaust gas recirculation cooler

*BA14.20-P-1018-01Q

12

Loosen the screw (8).

 Bolt, high pressure exhaust gas recirculation valve to bracket for high pressure exhaust gas recirculation cooler

*BA14.20-P-1010-01Q

13

Remove screws (2) in reverse order to tightening procedure.

Tightening procedure

AR01.20-P-5014-03OLC

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-P-1001-03A

14

Remove the cylinder head cover (1).

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

 Installation: Replace screws (2) and bushings made from aluminum with screws (2) and bushings made from steel.
Install new seals(3).
Remove sealing beads (9) at new seal.

15

Remove bracket (4).

When replacing the cylinder head cover (1).

 Bolt, bracket for engine cover to cylinder head cover

*BA01.10-P-1003-01D

16

Degrease sealing surfaces on the cylinder head, rear cap, and cylinder head cover (1) with a lint-free rag.

 Installation: Apply sealant (A) to the contact area between the cylinder head and rear cap on the cylinder head.

Assembly cleaner

*BR00.45-Z-1028-04A

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

17

Install in the reverse order.



Check

18

Check engine oil level, correct if necessary.



Engine 654 in model 205, 253
with code M014 (Engine uprated)

AP18.00-P-0101FA



Engine 654 in model 205, 253
except code M014 (Engine uprated)

AP18.00-P-0101FC

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

19

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

20

Install upper engine cover.

AR01.10-P-2405OLI

 Engine cover

Number

Designation

Engine 654

BA01.10-P-1003-01D

Bolt, bracket for engine cover to cylinder head cover

Nm

8

 Cylinder head cover

Number

Designation

Engine 654

BA01.20-P-1001-03A

Screw/bolt, cylinder head cover to cylinder head

Steel screws/bolts

Nm

8

 Sensors

Number

Designation

Engine 654

BA07.04-P-1022-02A

Bolt, holder for boost pressure sensor of low-pressure exhaust gas turbocharger to cylinder head cover

Nm

6

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1010-01Q

Bolt, high pressure exhaust gas recirculation valve to bracket for high pressure exhaust gas recirculation cooler

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1015-01Q

Screw, bracket for low-pressure exhaust gas recirculation cooler to cylinder head cover/low-pressure exhaust gas recirculation cooler/lifting lug

Stage 1

Nm

8

Stage 2

°

30

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1018-01Q

Screw, holder to high-pressure exhaust gas recirculation valve/high-pressure exhaust gas recirculation cooler

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01