Remove/install cylinder head cover

AR01.20-D-5014TSC

Remove/install cylinder head cover

18.02.2020

Engine

274 in model 907

1

Cylinder head cover

5

Shielding

9

Cap

2

Bracket

6

Oil separator

10

Screw

3

Electrical wiring harness

7

Bracket

11

Bracket

4

Cable duct

8

Bolts

N3/36

ME-SFI [ME] control unit

 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

 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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1

Clamp off ground line of on-board electrical system battery (G1).

AR54.10-D-0029TS

2

Remove cylinder head cover trim (1).

AR01.20-D-5015TSC

3

Remove engine oil filler neck.

4

Remove ME-SFI [ME] control unit (N3/36).

AR07.08-D-7011TSC

5

Remove electrical wiring harness (3) from bracket (2) and check clips.

If a clip is damaged,



replace clip.

6

Remove holder (2).

7

Remove cable duct (4).

AR01.00-S-2411-02EG

 Nut, line to starter

*BA15.30-N-1002-01W

 M6

*BA00.10-N-1002-01A

8

Remove shielding (5) of high-pressure pump.

AR07.02-S-0815-01EG

 Installation: Observe tightening procedure for shielding (5).

 Bolt for high-pressure pump shielding

*BA07.02-N-1002-01F

9

Remove fuel high-pressure pump.

AR07.02-D-1028TSC

10

Remove fuel injectors (Y62).

AR07.03-D-0004TSC

11

Remove oil separator (6) from cylinder head cover (1).

AR01.20-D-9750TSC

 The oil separator (6) is not removed completely.

12

Remove the vacuum pump.

AR43.05-S-1320EG

13

Remove ignition coils.

AR15.12-D-2003TSC

14

Remove front cap on cylinder head.

AR01.30-D-5700TSC

15

Remove screws/bolts (8) and remove bracket (7).

 Bolt, lifting eye to cylinder head

*BA01.30-N-1006-01X

 Bolt, lifting eye to cylinder head cover

*BA01.30-N-1007-01X

16

Remove screw/bolt (10) of bracket (11)

 M8

*BA00.10-N-1003-01A

17

Remove the cap (9) using a suitable tool.

 Installation: Install new cap (9).

18

Remove cylinder head cover screws/bolts (1) in the reverse order of the tightening procedure.

AR01.20-S-5014-03EG

Topical note

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

AH00.00-P-0020-01A

 Installation: Pay attention to tightening procedure for screws/bolts.
Replace screws/bolts.

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-N-1001-01W

19

Remove cylinder head cover (1) from cylinder head.

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 (1) and cylinder head. Use puller screw if necessary.
The sealing surfaces can be damaged otherwise.

 The cylinder head cover (1) and cylinder head create a unit and can therefore only be exchanged together.

 Installation: Observe notes on sealant path.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

20

Adjust position sensor of intake camshaft.

Only when replacing the cylinder head cover (1).

AR07.04-D-0056TSC

21

Adjust position sensor of the exhaust camshaft.

Only when replacing the cylinder head cover (1).

AR07.04-D-0057TSC

22

Adjust detachable parts on cylinder head cover (1).

Only when replacing the cylinder head cover (1).



Check

23

Check slide rail of timing chain in cylinder head cover (1).

If timing chain slide rail is damaged,



replace timing chain slide rail.

AR05.10-D-8480TSC

24

Check camshaft mounts in the cylinder head cover (1).

 The cylinder head cover (1) and cylinder head create a unit and can therefore only be exchanged together.

If galling or score marks are present,



replace cylinder head cover (1) and cylinder head.

AR01.30-D-5800TSC

25

Check camshafts.

If galling or score marks are present,



replace camshafts.

AR05.20-D-6992TSC



Clean

26

Clean sealing surfaces on cylinder head and cylinder head cover (1).

AR01.00-P-0050-01A

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

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

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

Loctite 7200

*BR00.45-Z-1038-04A

27

Install in the reverse order.



Check

28

Check engine oil level, correct if necessary.



AP18.00-D-0101TSC

 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

 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

29

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

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

23

32

Phosphated

Nm

21

29

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

38

Phosphated

Nm

36

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 274

BA01.20-N-1001-01W

Screw/bolt, cylinder head cover to cylinder head

Stage 1

Nm

10

Stage 2

°

90

 Cylinder head

Number

Designation

Engine 274 in model 907

BA01.30-N-1006-01X

Bolt, lifting eye to cylinder head

Nm

20

 Cylinder head

Number

Designation

Engine 274 in model 907

BA01.30-N-1007-01X

Bolt, lifting eye to cylinder head cover

Nm

20

 High pressure pump

Number

Designation

Engine 274 in model 907

BA07.02-N-1002-01F

Bolt for high-pressure pump shielding

Nm

20

 Starter

Number

Designation

Engine 274 in model 907

BA15.30-N-1002-01W

Nut, line to starter

M6

Nm

6

M8

Nm

15

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