ar0120d5014e

Remove/install cylinder head cover

Type ar · topic 01.20 · version 0105 · 2002-04-09

Applies to: ENGINE 611.981 /987 in MODELS 901.6, 902.6, 903.6, 904.6 ENGINE 612.981 in MODEL 902.6, 903.6, 904.6, 905.6 ENGINE 611.983 in MODEL 690.6

Where it sits

Function group 1 Engine › 01 Complete engine, crankcase ventilation, cylinder head, crankcase › 01.20 Crankcase ventilation, cylinder head cover — Series 611 (models 981, 983, 987) · Series 690 (models 6**) · Series 901 (models 6**) · Series 902 (models 6**) · Series 903 (models 6**) · Series 904 (models 6**) · Series 905 (models 6**)

EinPAS 15 Engine › 15.16 Cylinder head › 15.16.30 Cylinder head cover — Series 611 (models 981, 983, 987) · Series 690 (models 6**) · Series 901 (models 6**) · Series 902 (models 6**) · Series 903 (models 6**) · Series 904 (models 6**) · Series 905 (models 6**)

Also applies to engines/gearboxes: 612 981

AR01.20-D-5014E

Remove/install cylinder head cover

6.4.99

ENGINE 611.981 /987 in MODELS 901.6, 902.6, 903.6, 904.6

ENGINE 612.981 in MODEL 902.6, 903.6, 904.6, 905.6

ENGINE 611.983 in MODEL 690.6

Remove/install cylinder head cover

D01.20-0004-06

Engine 611.981/983/987

1 Injector

2 Crankcase ventilation line

3 Camshaft position sensor connector

4 Screw

5 Cable duct with engine wiring harness

6 Outlet line

7 Cylinder head cover

8 Gasket

9 Gasket

10 Glow plug connector

11 Screw

Remove/install cylinder head cover

D01.20-1005-06

Engine 612.981

1 Injector

2 Crankcase ventilation line

3 Camshaft position sensor connector

4 Screw

5 Cable duct with engine wiring harness

6 Outlet line

7 Cylinder head cover

8 Gasket

9 Gasket

10 Glow plug connector

11 Screw

12 Charge air distribution pipe

	Remove
1.1	Remove top part of charge air distribution pipe	On engine 611.981/983/987	AR09.41-D-1312A
1.2	Detach charge air distribution pipe (12) at cylinder head and place to the side with engine wiring harness connected	 Engine 612.981 with code MD1, MS5 and MF8 (exhaust gas recirculation)  The engine wiring harness does not need to be separated at the vehicle side.	AR09.41-D-1310A
2	Remove cylinder head cover trim panel		AR01.20-D-5015A
3	Remove injection lines		AR07.16-D-1080A
4	Remove injectors (1)	 On engine 611.981 as of 446355 611.987 as of 446784 612.981 as of 445787 mark the installation sequence when removing the injectors. Otherwise the classification must be entered in the engine control module with the DAS. If the injectors are replaced, these must always be classified.	AR07.16-D-1000A
5	Detach crankcase ventilation line (2)
6	Unplug connector (3) at camshaft position sensor
7	Unplug connectors (10) at the glow plugs
8	Unscrew bolt (4), unclip cable duct (5) together with engine wiring harness at cylinder head cover (7) and at rail, and place to the side	 Pay attention to ground cable (arrow).
9	Detach outlet line (6)
10	Take off cylinder head cover (7)	If cylinder head cover is replaced 
		Fit existing crankcase ventilation, camshaft position sensor and bracket.
	Install
11	Fit on cylinder head cover (7)	 Inspect gaskets of cylinder head cover (8, 9), replace if necessary. Do not fully tighten bolts as injectors are aligned by means of the cylinder head cover. Otherwise, gas leakages of the injectors may occur in the cylinder head, and also impermissible stresses in the injection lines
12	Install injectors (1)	 First of all, insert all injectors and tensioning claws. Insert new bolts and tighten in the following order: Injector 2-3-4-1 (engine 611.981/983/987) Injector 3-4-5-2-1 (engine 612.981)	AR07.16-D-1000A
13	Tighten bolts (11) of cylinder head cover (7)		*BA01.20-P-1001-01A
14	Plug in connectors (10) at the glow plugs
15	Install cable duct (5) with engine wiring harness at cylinder head cover, tighten bolt (4)	 Pay attention to ground cable (arrow).
16	Plug in connector (3) at camshaft position sensor
17	Fit on return flow line (6)
18	Fit on crankcase ventilation line (2)
19	Install injection lines	 Counterhold with wrench at threaded connection of injectors (1).	AR07.16-D-1080A
20	Install trim panel of cylinder head cover		AR01.20-D-5015A
21.1	Install top part of charge air distribution pipe	On engine 611.981/983/987	AR09.41-D-1312A
21.2	Fit charge air distribution pipe (12) onto cylinder head	 Engine 612.981 with code MD1, MS5 and MF8 (exhaust gas recirculation)	AR09.41-D-1310A
Danger!	Risk of accident as vehicle may start off by itself with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns	Secure vehicle to prevent it from moving off by itself. Wear closed and close-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
22	Inspect for oil leaks	 Run engine until warm, switch off and check for leaks.

 Crankcase ventilation, cylinder head cover

Number	Designation		Engine 611.981/ 983/ 987	engine 612.981


BA01.20-P-1001-01A	Bolt, cylinder head cover to cylinder head	NM	9	9

Referenced documents

ar0120d5015a Remove/install trim panel of cylinder head cover
ar0716d1000a Remove/install injectors
ar0716d1080a Remove/install injection lines of common rail diesel injection (CDI)
ar0941d1310a Remove/install charge air distribution pipe
ar0941d1312a Remove/install top section of charge air distribution pipe
as0000z000501a 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.