Remove/install front cover on cylinder head

AR01.30-P-5700CW

Remove/install front cover on cylinder head

16.5.11

22.4.09

Value changed: Bolt, lifting eye to cylinder head

*BA01.30-P-1005-01J

 

Remove/install

1.1

Detach front trim panel for cylinder head cover toward top

Engine 271.9

1.2

Remove engine trim panel

Engine 271.8

 Grasp with both hands and pry off.

 Installation: When placing the engine cover, ensure that the seal is correctly seated at the oil filler neck. The seal should not be pressed down by the engine cover, but must lie against the engine cover .

2.1

Remove engine vacuum duct

Engine 271.9

AR09.10-P-1150CW

2.2

Remove air guide between air filter housing and turbocharger

Engine 271.8

AR09.10-P-1150EVO

3

Remove coolant temperature control housing

AR20.10-P-2460CW

4

Remove wideband silencer

Engine 271.9

AR09.41-P-6825CW

5

Remove poly-V belt and guide pulley

 Engine 271.8: guide pulley next to the power steering pump.

AR13.20-P-0001CW

6

Remove cylinder head cover

AR01.20-P-5014CW

7

Disconnect electrical connection on intake camshaft solenoid (Y49/1) and exhaust camshaft solenoid (Y49/2)

8

Unclip boost pressure control pressure transducer (Y31/5) with vacuum line from the front cover (4) and front lifting eye (5)

Engine 271.8

 Put boost pressure control pressure transducer (Y31/5) with attached vacuum line to one side.

9

Detach front lifting eyes (5) on right and left at cylinder head



*BA01.30-P-1005-01J



*BA01.30-P-1006-01J

10

Remove bolt (3a) and remove ground line (3)



*BA01.30-P-1001-01J

11

Remove bolts (4a) and take off the front cover (4) from the cylinder head

 Installation: Coat sealing surface on front cover (4) to cylinder head with sealant.

AR01.00-P-0050-01A

 Installation: Install new sealing ring (4b).



*BA01.30-P-1007-01J

Loctite 5970 sealant

*BR00.45-Z-1013-01A



Clean

12

Clean sealing surfaces

 Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

13

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

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

AS00.00-Z-0005-01A

14

Conduct engine test run and check engine for leaks while it is running

Number

Designation

Engine
271

BA01.30-P-1001-01J

Bolt, ground line to front cover

M6

Nm

8

BA01.30-P-1005-01J

Bolt, lifting eye to cylinder head

M8

Nm

13

BA01.30-P-1006-01J

Bolt, lifting eye to front cover and camshaft bearing housing

M6

Nm

9

M8

Nm

20

BA01.30-P-1007-01J

Bolt, front cover to cylinder head

M6

Nm

9

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite 5970 sealant

A 003 989 98 20

BR00.45-Z-1038-04A

Loctite 7200

Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de

BR00.45-Z-1046-04A

Loctite 7063 cleaning spray (150 ml)

A 001 986 71 71 10