Remove/install cylinder head cover

AR01.20-P-5014MFF

Remove/install cylinder head cover

06.03.2020

Engine

654 in model 118, 177, 247

Modification notes

05.08.2019

Information document AH00.00-P-0500-01MNE, added.

Operation step 11.

05.08.2019

Information document AH05.20-P-1000-09SZ, added.

Operation step 11.

1

Cylinder head cover

7

Bracket

10

Electrical connector

5

Screw

8

Screw

11

Heat shield

6

Electrical wiring harness

1

Cylinder head cover

2

Bolts

3

Sealing rings

9

Sealing beads

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove engine charge air duct from exhaust gas turbocharger.

AR09.41-P-8622MFF

 Installation: Only install upper engine cover after the leak test.

2

Remove fuel injectors.

AR07.16-P-1020MFF

3

Remove rail.

AR07.03-P-1010MFF

4

Remove air intake line upstream of exhaust gas turbocharger.

AR09.40-P-0500MFF

5

Remove temperature sensor control unit from cylinder head cover (1) and place to one side.

AR49.20-P-0015MFF

6

Remove the camshaft Hall sensor.

AR15.10-P-1999MFF

7

Release and disconnect electrical connector(10).

8

Remove screw (8) and place bracket (7) with clipped in electric line to one side.


Do not crush or kink electric line or subject it to tension.
This will result in damage to electric line and impair its function.

9

Unscrew screw (5) and place electrical wiring harness (6) to one side.

 M61

*BA00.10-P-1002-04A

10

Remove screws (2) in reverse order to tightening procedure.

Bolt tightening procedure for cylinder head cover

AR01.20-P-5014-03OLC

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-P-1001-03A

11

Remove the cylinder head cover (1).

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

General information on checking camshafts and bearing points of camshafts

AH05.20-P-1000-09SZ

 Installation: Install new seals(3).
Remove sealing beads (9) at new seal.

12

Modify heat shield (11).

When replacing the cylinder head cover (1).

 M61

*BA00.10-P-1002-04A

13

Degrease sealing surfaces at cylinder head, rear cover and cylinder head cover (1) with lint-free rag.

 Installation: Apply sealant (arrows A) to contact area between cylinder head and rear cover at cylinder head.

Assembly cleaner

*BR00.45-Z-1028-04A

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

14

Install in the reverse order.



Check

15

Check engine oil level, correct if necessary.



AP18.00-P-0101FA

 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

16

Perform engine test run and check engine for leak tightness.

17

Install upper engine cover.

AR01.10-P-2405MFF

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Cylinder head cover

Number

Designation

Engine 654

BA01.20-P-1001-03A

Screw/bolt, cylinder head cover to cylinder head

Steel screws/bolts

Nm

8

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-1028-04A

Assembly cleaner

A 000 986 56 01