Remove/install cylinder head cover

AR01.20-P-5014VA

Remove/install cylinder head cover

18.02.2020

Engine

272 in model 171

Left cylinder head cover

1

Purge line

2

Fuel line

3

Oil separator

4

Ground cable

5

Bolts

6

Rear left engine suspension lug

7

Rubber mount

T1/4

Cylinder 4 ignition coil

T1/5

Cylinder 5 ignition coil

T1/6

Cylinder 6 ignition coil

 

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

 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

1

Open hood

Opening engine hood, moving to upright position and closing

AR88.40-P-1000V

 Do not close the engine hood until after the leak check.

2

Remove the front and central sections of the lower engine compartment paneling

Remove/install lower engine compartment lining

AR61.20-P-1105V

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

3

Drain coolant at radiator

AR20.00-P-1142VA

Topical note

Notes on coolant

AH20.00-N-2080-01A

4

Remove air filter housing

AR09.10-P-1150VA

5

Remove poly-V belt

AR13.22-P-1202VA

6

Remove poly-V belt tensioning device

AR13.25-P-3200VA

7

Remove coolant thermostat

AR20.10-P-2460VA

8

Remove oil filter housing

AR18.20-P-3471VA

9

Remove power steering expansion reservoir

AR46.25-P-1000VA

10

Remove front cover at left cylinder head

AR01.30-P-5700VB

11

Disconnect purge line (1) from engine and place to the side

12

Relieve fuel pressure through service valve

AR07.03-P-1460-01VA

 Protective cap to service valve

*BA07.03-P-1004-01B

 Pressure hose

*119589046300

13

Disconnect the fuel line (2) from the engine

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01B

14

Remove cylinder 4 to 6 (T1/4–T1/6) ignition coils on the left cylinder head

AR15.12-P-2003VA

15

Remove oil separator (3)

AR01.20-P-9750VA

16

Detach ground line (4) from cylinder head cover.

 Screw/bolt, ground line to front cover

*BA01.30-P-1001-01O

17

Detach cable duct from the cylinder head cover, unscrew the screws (5) for this purpose

 Screw/bolt, cable duct to cylinder head cover

*BA01.30-P-1012-01O

 Screw/bolt, cable duct to lifting eye

*BA01.30-P-1013-01O

18

Detach rear left engine suspension lug (6)

 Screw/bolt, lifting eye to cylinder head

*BA01.30-P-1005-01O

19

Detach the rubber mount (7) from the cylinder head cover

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

*BA01.30-P-1011-01O

20

Loosen bolts for cylinder head cover in reverse order of tightening procedure and remove them

AR01.20-P-5014-03VA

 Screw/bolt, cylinder head cover to cylinder head

*BA01.30-P-1004-01O

21

Carefully pry the cylinder head cover off the cylinder head with a suitable tool

Notes on sealant path for cylinder head cover

AH01.30-P-1000-08MM

 Installation: Apply sealant to the cylinder head cover: 

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500



Clean

22

Clean the sealing surfaces on the cylinder head and the cylinder head cover

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

 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

BA01.30-P-1001-01O

Screw/bolt, ground line to front cover

M6

Nm

9

 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-1005-01O

Screw/bolt, lifting eye to cylinder head

M8

Nm

20

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1011-01O

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

M6

Nm

9

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1012-01O

Screw/bolt, cable duct to cylinder head cover

M6

Nm

9

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1013-01O

Screw/bolt, cable duct to lifting eye

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

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