Remove/install cylinder head cover

AR01.20-D-5014R

Remove/install cylinder head cover

18.11.2016

Engine

646 in model 909

Modification notes

27.10.2016

Hose clamp pliers 003 589 03 37 00 added.

Operation step 4, 16

Shown on vehicle with code MS9(Engine version EURO 4)

1

Cylinder head cover

2

Fuel hose

3

Cylinder head

4

Oil separator

B6/19

Rpm sensor

 Danger !

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



Remove

1

Remove cylinder head cover trim (1)

AR01.20-D-5014-02R

2

Remove fuel injectors

AR07.16-D-1000R

3

Disconnect engine wiring harness

AR15.18-D-1000-04R

 Pliers

*611589003700

4

Detach hose at the oil separator (4)

 Hose clamp pliers

*003589033700

5

Remove cylinder head cover (1) screw/bolts

6

Raise cylinder head cover (1) until the fuel hose (2) is accessible

7

Detach fuel hose (2) at cylinder head cover (1) and remove cylinder head cover (1)

8

Clean sealing surfaces on cylinder head (1) and cylinder head cover (3) using a lint-free cloth

9

Remove oil separator (4)

When replacing the cylinder head cover (1).

AR01.20-D-9750R

10

Remove rpm sensor (B6/19)

When replacing the cylinder head cover (1).

AR15.12-D-2145R



Install

11

Install rpm sensor (B6/19)

When replacing the cylinder head cover (1).

AR15.12-D-2145R

12

Install oil separator (4)

When replacing the cylinder head cover (1).

AR01.20-D-9750R

13

Mount fuel hose (2) on cylinder head cover (1)

 Ensure correct seating of the fuel hose (2).

14

Install cylinder head cover (1)

 Replace seals.

15

Tighten cylinder head cover (1) screw/bolts

 Bolt, cylinder head cover to cylinder head

*BA01.20-N-1001-01M

16

Mount hose on the oil separator (4)

 Hose clamp pliers

*003589033700

17

Attach engine wiring harness

AR15.18-D-1000-04R

 Pliers

*611589003700

18

Install fuel injectors

AR07.16-D-1000R

 Danger !

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

19

Carry out engine test run and check engine for leaktightness while it is running

20

Install trim panel of cylinder head cover (1)

AR01.20-D-5014-02R

 Bolt, trim panel to cylinder head cover

*BA01.20-N-1003-01M

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 646 in model 909

BA01.20-N-1001-01M

Bolt, cylinder head cover to cylinder head

Nm

8

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 646 in model 909

BA01.20-N-1003-01M

Bolt, trim panel to cylinder head cover

Nm

10