Removing, installing cylinder head cover · ar0120s5014d · Mercedes-Benz WIS

AR01.20-S-5014D

Removing, installing cylinder head cover

25.8.98

ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)

ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

Removing, installing cylinder head cover

S01.20-2502-06

1 Injection line

2 Bolt

3 Tensioning claw

4 Bolt

5 Cylinder head cover

6 Cylinder head

7 Bracket

8 Camshaft Hall sensor

9 Gasket

10 Gasket

11 Leak oil line

12 Locking element

13 Bolt

14 Seal

Y20 Injector 1

Y21 Injector 2

Y23 Injector 3

Y24 Injector 4

 	Removing, installing
 Danger!	Risk of explosion from ignition. Risk of poisoning from inhaling and swallowing fuel. Risk of injury as a result of fuel coming into contact with skin and eyes.	No fire, naked flame or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
1	Remove injectors (Y20, Y21, Y22, Y23)	 Installation: to avoid any stresses occurring when installing the injection lines, these should be fitted on properly before installing the injectors	AR07.16-S-1000A
			*602589003300
			*611589013300
			*611589006800
			*000589266800
			*001589760900
	Notes on injectors	 Clean injector recesses and nozzles with a wire brush. Grease injector recesses with special grease, clean injector recesses with a round brush and cylinder brush, blow out and cover over. Seal nozzle recesses with a pin before cleaning.  Set brush length to about 3 mm for cleaning the sealing seat.  Replace injector seal (14) and bolts (2) of the tensioning claws (3).	AH07.16-P-1000-01A
		Special grease	*BR00.45-Z-1036-06A
2	Take off bracket (7) of EGR valve at the cylinder head cover (5)		*BA01.20-P-1004-01A
			*001589760900
3	Unplug connector at camshaft Hall sensor (8)
4	Unplug lines running over cylinder head cover (5)	 Place lines to the side
5	Unscrew bolts (4) of cylinder head cover (5)	 Installation: do not fully tighten bolts (4) as injectors (Y20 - Y23) are aligned by means of the cylinder head cover (5). Otherwise, this may result in gas leakages and the injectors (Y20 - Y23) baking tight in the cylinder head (6), and may also result in impermissible stresses in the injection lines (1).
			*BA01.20-P-1001-01A
			*001589760900
6	Remove cylinder head cover (5)	 Installation: clean sealing surfaces. Replace gaskets (9, 10) of cylinder head cover (5). Ensure scrupulous cleanliness.
7.1	Remove camshaft Hall sensor (8)	 Only if cylinder head cover is replaced	AR15.10-S-2000B
8	Install in the reverse order

 Crankcase ventilation, cylinder head cover

Number	Designation		Engine 611.980


BA01.20-P-1001-01A	Bolt of cylinder head cover to cylinder head	Nm	9
BA01.20-P-1004-01A	Bolt of bracket to cylinder head cover	Nm	16

001 589 76 09 00

Impact extractor

External torx set

Brake caliper brush

Round brush

000 589 26 68 00

602 589 00 33 00

611 589 00 68 00

Extraction claw

611 589 01 33 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1036-06A	Special grease	A 001 989 42 51 10

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