Remove/install cylinder head cover

AR01.20-P-5014TS

Remove/install cylinder head cover

18.02.2020

Engine

272.922/943/944/964/972 in model 211

Left cylinder head cover

Engine

272.943/964, 273.960 in model 219

Left cylinder head cover

Engine

273.960/962 in model 211

Left cylinder head cover

1

Oil filter housing

6

Feed duct

10

Cylinder head cover

2

Power steering expansion reservoir

7

Fuel line

10a

Heat shield

3

Front cover

8

Fuel distributor

11

Engine suspension lug

4

Purge line

9

Ground cable

12

Rubber mount

5

Oil separator

 

Remove/install

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

1

Turn key in ignition lock to position "0"

2

Remove lower engine compartment paneling

Model 211

AR61.20-P-1105T

Model 219

AR61.20-P-1105TX

3

Drain coolant at radiator

AR20.00-P-1142TS

Topical note

Notes on coolant

AH20.00-N-2080-01A

4

Remove air filter housing

AR09.10-P-1150TS

5

Remove poly-V-belt and poly-V belt tensioning device

AR13.20-P-0001TS

6

Remove coolant thermostat

AR20.10-P-2460TS

7

Remove oil filter housing (1)

AR18.20-P-3471TS

8

Remove expansion reservoir (2)

Model 211

AR46.25-P-1000TS

Model 219

AR46.25-P-1000TX

9

Remove front cover (3) at left cylinder head

AR01.30-P-5700TS

10

Disconnect purge line (4) at the connecting point (arrow), unclip from brackets at oil separator (5) and feed duct (6) and set aside

11

Relieve fuel pressure with pressure hose through service valve

AR07.03-P-1460-01VA

 Protective cap to service valve

*BA07.03-P-1004-01B

 Pressure hose

*119589046300

12

Detach fuel line (7) on fuel distributor (8)

 Collect escaping fuel with an absorbent rag!

 Seal connections with stop plugs immediately.

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01B

 Record plug

*129589009100

13

Remove ignition coils at left cylinder head

AR15.12-P-2003TS

14

Remove oil separator (5)

AR01.20-P-9750TS

15

Detach ground line (9) from the cylinder head cover (10)

 Screw/bolt, ground line to front cover

*BA01.30-P-1001-01O

16

Remove rear left engine lifting lug (11)

 Screw/bolt, lifting eye to cylinder head

*BA01.30-P-1005-01O

 Screw/bolt, feed duct to engine suspension lug

*BA15.18-P-1003-01B

17

Detach feed duct (6) from the cylinder head cover (10)

 Screw/bolt, feed duct to cylinder head cover

*BA15.18-P-1002-01B

18

Detach front rubber mount (12) of the air filter housing from the cylinder head cover (10)

 Screw/bolt, air filter housing rubber mount to cylinder head cover

*BA01.30-P-1011-01O

19

Remove heat shield (10a)

 Screw/bolt, heat shield to cylinder head

*BA01.30-P-1017-01O

20

Loosen screws for cylinder head cover (10) in reverse order of tightening procedure and remove them

Bolt tightening procedure for cylinder head cover
Engine 272

AR01.20-P-5014-03VA

Bolt tightening procedure for cylinder head coverEngine 273

AR01.20-P-5014-03SX

 Screw/bolt, cylinder head cover to cylinder head

*BA01.30-P-1004-01O

21

Pry off cylinder head cover (10) from cylinder head carefully

Notes on sealant path for cylinder head cover

AH01.30-P-1000-08MM


Do not pound in tool for prying off between cylinder head cover (10) and cylinder head.
The sealing surfaces will be damaged otherwise.

 Installation: Apply sealant to the cylinder head cover (10):

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500



Clean

22

Clean sealing surfaces on cylinder head and on cylinder head cover (10)

Remove sealant

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces will be damaged otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

23

Install in the reverse order



Check

 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

24

Perform an engine test run and check engine for leaktightness

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1001-01O

Screw/bolt, ground line to front cover

M6

Nm

9

9

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1004-01O

Screw/bolt, cylinder head cover to cylinder head

M7

Stage 1

Nm

12

12

Stage 2

°

90

90

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1005-01O

Screw/bolt, lifting eye to cylinder head

M8

Nm

20

20

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1011-01O

Screw/bolt, air filter housing rubber mount to cylinder head cover

M6

Nm

9

9

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1017-01O

Screw/bolt, heat shield to cylinder head

M6

Nm

9

9

 Injection nozzles, injection valves, lines

Number

Designation

Engine 272

Engine 273

BA07.03-P-1001-01B

Union nut, fuel line to fuel distributor

Nm

20

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 272

Engine 273

BA07.03-P-1004-01B

Protective cap to service valve

Plastic

Nm

2

–

Metal

Nm

15

–

 Engine wiring harness

Number

Designation

Engine 272

Engine 273

BA15.18-P-1002-01B

Screw/bolt, feed duct to cylinder head cover

Nm

8

8

 Engine wiring harness

Number

Designation

Engine 272

Engine 273

BA15.18-P-1003-01B

Screw/bolt, feed duct to engine suspension lug

Nm

8

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-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09