Remove/install left cylinder head cover

AR01.20-D-5013TSV

Remove/install left cylinder head cover

13.09.2018

Engine

642 in model 907

1

Cylinder head cover

2

Engine charge air duct

11

Screw

12

Fuel line

14

Fuel hose

15

Fuel hose

16

Fuel filter

17

Screw

18

Electrical wiring harness

19

High pressure pump

7

Screw

22

Bracket

25

Bracket

26

Hose

27

Hose

28

Bracket

29

Bracket

34

Glow output stage

1

Cylinder head cover

20

Screw

21

Cover

22

Bracket

23

Bolts

24

Cover

 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove screw (7) and press bracket (25) with hose (26) forward.

2

Remove engine charge air duct (2) and hang to one side.

AR09.41-D-8950TSV

3

Remove rail of the left cylinder head.

AR07.03-D-1011TSV

4

Remove injectors of the left cylinder head.

AR07.16-D-1020TSV

5

Remove bracket (29) with glow output stage (34) and place to one side.

 Unclip hose (27) from bracket (28). Do not disconnect electrical connectors of glow output stage (34).

 Bolt, bracket to charge-air distributor

*BA09.41-N-1002-01O

6

Remove high-pressure line to rail.

AR07.16-D-1004TSV

7

Remove fuel hose (14) from high-pressure pump (19).

 Seal openings with suitable stop plug.

 Installation: Check clamp for damage.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

In the case of damage,



Replace clamp.

8

Remove fuel hose (15) from fuel filter (16).

 Seal fuel hose (15) and connection on fuel filter (16) with suitable stop plugs.

 Installation: Check clamp for damage.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

In the case of damage,



Replace clamp.

9

Remove electrical wiring harness (18) from cylinder head cover (1).

 Installation: Check retaining clamps of the electrical wiring harness (18) for damage.

In the case of damage,



Replace retaining clips.

10

Remove screws (11, 17) and position fuel line (12) outside the working area.

11

Remove screws (23) and remove bracket (22).

 Bolt, holder to oil filter housing and cylinder head cover

*BA18.20-N-1003-01O

12

Loosen and remove screws (20) in stages and in reverse order of the tightening procedure for a cooled engine.

Bolt tightening procedure for cylinder head cover

AR01.20-D-5014-03SF

 Removal:
Loosen screws (20) only for a cooled engine.
Otherwise, distortion of the cylinder head cover (1) may occur.

 Installation:
Observe tightening pattern and tightening specifications for screw/bolts (20).
Distortion of the left cylinder head cover (1) can occur otherwise and lead to damage to the camshafts.

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-N-1001-01O

13

Remove the cylinder head cover (1).

Notes on sealant path for cylinder head cover

AH01.30-N-1000-08SE

 Removal:
Pry off cylinder head cover (1) from the cylinder head with the greatest of care.
Otherwise, the cylinder head cover (1) may be damaged.

 Removal: Carefully pry off the cylinder head cover (1) to the corners (arrows) from the cylinder head with a suitable tool.

 A new cylinder head cover (1) can be installed only in combination with the cylinder head.

 Installation: Install new caps (21, 24).
Remove sealant residues from the sealing surfaces of the cylinder head cover (1) and cylinder head.
Lubricate bearing points for camshaft bearing.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

Loctite 7200

*BR00.45-Z-1038-04A

 Application gun

*112589002500

14

Install in the reverse order.



Check

 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

15

Perform engine test run and check engine in the area of the cylinder head cover (1) for leak tightness.

 Visual inspection only.

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 642 in model 907

BA01.20-N-1001-01O

Screw/bolt, cylinder head cover to cylinder head

Stage 1, apply

Nm

4

Stage 2, initial torque

Nm

6

Stage 3, final torque

Nm

8

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1002-01O

Bolt, bracket to charge-air distributor

Nm

9

 Engine lubrication, oil filter housing

Number

Designation

Engine 642

BA18.20-N-1003-01O

Bolt, holder to oil filter housing and cylinder head cover

Nm

14

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