Remove/install cylinder head cover trim panel

AR01.20-P-5015MFE

Remove/install cylinder head cover trim panel

04.03.2020

Engine

608 in model 118, 177, 247

Modification notes

18.02.2020

Document completely revised.

Shown on model 177

3

Bracket

7

Clamps

4

Electrical connector

8

Bolts

5

Electrical wiring harness

16

Screw

6

Bolts

17

Cylinder head cover upper part

Shown on model 177

10

Electrical connector

13

Nuts

18

Cylinder head cover lower section trim

11

Electrical wiring harnesses

14

Screw

Y73/2

Low-temperature circuit switchover valve 2

12

Hose

15

Filler pipe

18

Cylinder head cover lower section trim

19

Supports

20

Bolts

 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

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Switch off ignition and store transmitter key outside of transmitter range (min. 2 m).

2

Remove the charge air cooler and place to one side with lines attached.

AR09.41-P-0105MFE

3

Unclip bleed line from bracket (3).

4

Release and disconnect electrical connectors (4) and unclip wiring harness from the cylinder head cover upper part (17).

5

Unclip electrical wiring harness (5) from the cylinder head cover upper part (17).

6

Remove screw (16).

 Bolt, holder for charge air line/fuel line to intake air throttling

*BA09.41-P-1001-01CA

7

Remove bolts (6) and remove bracket.

 Bolt, holder for charge air line/fuel line to intake air throttling

*BA09.41-P-1001-01CA

8

Open clips (7).

9

Remove screws (8) and remove cylinder head cover upper part (17).

 Installation: Tighten screws (8) slightly by hand and fully tighten only after the clips (7) are closed.

 Bolt, upper cover to oil separator

*BA01.20-P-1002-03D

10

Unclip low-temperature circuit switchover valve 2 (Y73/2) and place to one side with connected lines.


Do not crush or kink or subject lines to tension.
Failure to do this will cause damage to the lines and impair their function.

11

Remove top charge air cooler bracket.

 Bolt, holder (top) charge air cooler to crankcase/cylinder head

*BA09.41-P-1001-03I

12

Release and disconnect electrical connectors (10).

13

Unclip electrical wiring harnesses (11) at cylinder head cover lower section trim (18).

14

Remove nuts (13).

 Nut, lower cover to stud bolt (for rail)

*BA01.20-P-1003-03D

15

Unscrew screw (14).

 M6

*BA00.10-P-1002-01A

16

Remove filler neck cap with attached oil dipstick.

17

Pull cylinder head cover lower section trim (18) forward slightly at the bottom until it is clear from the stud bolts of the nuts (13).

 Installation: Ensure hose (12) and filler pipe (15) are correctly seated at cylinder head cover lower section trim (18).

18

Unclip hose (12) at underside, remove filler pipe (15) under filler neck and seal with suitable stop plugs.

 Record plug

*129589009100

19

Remove cylinder head cover lower section trim (18).

20

Unscrew bolts (20) and transfer supports (19).

When installing a new cylinder head cover lower part (18).

 Installation:
Screw in screws (20) until the bolt head rests with zero clearance on the surface of the respective support (19) and then continue turning by 900.
If bolts (20) are screwed in too far, foam of supports (19) will be damaged.

21

Check that supports (19) are firmly seated on cylinder head cover lower section trim (18).

When installing a new cylinder head cover lower part (18).

If there is a problem,



Correct seating of the supports (19) and install new supports (19).

22

Install in the reverse order.

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

Number

Designation

Model all (4xWD, CAR, smart)

BA00.10-P-1002-01A

M6

8.8

Galvanized

Nm

9

Phosphated

Nm

9

10.9

Galvanized

Nm

13

Phosphated

Nm

12

12.9

Galvanized

Nm

16

Phosphated

Nm

14

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 608

BA01.20-P-1002-03D

Bolt, upper cover to oil separator

Nm

9

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 608

BA01.20-P-1003-03D

Nut, lower cover to stud bolt (for rail)

M8

Nm

21

 Charge air pipe/charge air cooling

Number

Designation

Engine 608

BA09.41-P-1001-01CA

Bolt, holder for charge air line/fuel line to intake air throttling

M6

Nm

10

 Charge air cooler

Number

Designation

Engine 608

BA09.41-P-1001-03I

Bolt, holder (top) charge air cooler to crankcase/cylinder head

M8

Nm

25