Remove/install cylinder head cover

AR01.20-P-5014TX

Remove/install cylinder head cover

18.02.2020

Engine

272.985 in model 211.057/257, 219.357

Left cylinder head cover

Modification notes

12.04.2018

Notes updated.

Entire document along with operation steps 9, 10, 17, and 21.

12.04.2018

Operation step added.

Operation step 8.

1

Power steering expansion reservoir

6

Feed duct

10

Cylinder head cover

2

Oil filter housing

7

Fuel line

10a

Heat shield

3

Front cover

8

Diagnostic socket

11

Vacuum pump

5

Oil separator

9

Ground cable

21

Rail

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

 

Remove/install

1

Remove air filter housing.

AR09.10-P-1150TS

2

Drain coolant at radiator.

AR20.00-P-1142TS

3

Remove the poly-V belt and the clamping device.

AR13.20-P-0001TS

4

Remove the coolant thermostat.

AR20.10-P-2460TS

5

Remove the power steering expansion reservoir (1).

Engine 272.985 in model 211.057/257Left cylinder head cover

AR46.25-P-1000TS

Engine 272.985 in model 219.357Left cylinder head cover

AR46.25-P-1000TX

6

Remove the oil filter housing (2).

AR18.20-P-3471TS

7

Remove front cover (3) at left cylinder head.

AR01.30-P-5700TS

8

Disconnect ground line from battery.

Engine 272.985 in model 219.357Left cylinder head cover

AR54.10-P-0003TX

Engine 272.985 in model 211.257Left cylinder head cover

AR54.10-P-0003TA

Engine 272.985 in model 211.057Left cylinder head cover

AR54.10-P-0003T

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

9

Relieve fuel pressure at service connection (8).

AR07.03-P-1460-01VA

 Protective cap to service valve

*BA07.03-P-1004-01B

 Pressure hose

*119589046300

10

Remove fuel line (7) at service connection (8) and seal openings with suitable stop plugs.

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 Collect escaping fuel using suitable means.

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01B

 Record plug

*129589009100

11

Remove oil separator (5).

AR01.20-P-9750TS

12

Remove ground line (9) from cylinder head cover (10).

 Screw/bolt, ground line to cylinder head cover

*BA01.30-P-1010-01O

13

Remove feed duct (6) from intake manifold, cylinder head cover (10), and engine lifting lug.

 Screw/bolt, feed duct to resonance intake manifold

*BA15.18-P-1001-01B

 Screw/bolt, feed duct to cylinder head cover

*BA15.18-P-1002-01B

 Screw/bolt, feed duct to engine suspension lug

*BA15.18-P-1003-01B

14

Remove rail (21).

AR07.03-P-1010TX

15

Remove vacuum pump (11).

AR43.05-P-1320TY

16

Remove heat shield (10a).

 Screw/bolt, heat shield to cylinder head

*BA01.30-P-1017-01O

17

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

AR01.20-P-5014-03VA

Topical note

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

AH00.00-P-0020-01A

 Screw/bolt, cylinder head cover to cylinder head

*BA01.30-P-1004-01O

18

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 tool for prying off in between cylinder head cover (10) and cylinder head.
This damages the sealing surfaces.

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

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500



Clean

19

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

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
This damages the sealing surfaces.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

20

Install in the reverse order.



Check

 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

21

Carry out an engine test run; check engine for leak tightness while doing so.

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1004-01O

Screw/bolt, cylinder head cover to cylinder head

M7

Stage 1

Nm

12

Stage 2

°

90

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1010-01O

Screw/bolt, ground line to cylinder head cover

M6

Nm

9

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1017-01O

Screw/bolt, heat shield to cylinder head

M6

Nm

9

 Injection nozzles, injection valves, lines

Number

Designation

Engine 272

BA07.03-P-1001-01B

Union nut, fuel line to fuel distributor

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 272

BA07.03-P-1004-01B

Protective cap to service valve

Plastic

Nm

2

Metal

Nm

15

 Engine wiring harness

Number

Designation

Engine 272

BA15.18-P-1001-01B

Screw/bolt, feed duct to resonance intake manifold

Nm

8

 Engine wiring harness

Number

Designation

Engine 272

BA15.18-P-1002-01B

Screw/bolt, feed duct to cylinder head cover

Nm

8

 Engine wiring harness

Number

Designation

Engine 272

BA15.18-P-1003-01B

Screw/bolt, feed duct to engine suspension lug

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-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