Remove/install cylinder head cover

AR01.20-S-5014PD

Remove/install cylinder head cover

18.02.2020

Model

470, 471 with engine 699

Modification notes

28.11.2019

Method extended

Operation steps 9, 11, 20

1

Bolts

2

Cylinder head cover

Shown on engine 699.301

2

Cylinder head cover

7

Bracket

12

Bolts

3

Bracket

8

Bolts

13

Bracket

4

Bolts

9

Fuel lines

14

Screw

5

Screw

10

Lines

15

Electrical connector

6

Electrical wiring harness

11

Electrical connector

Shown on engine 699.305

2

Cylinder head cover

9

Fuel lines

14

Screw

3

Bracket

10

Lines

15

Electrical connector

6

Electrical wiring harness

11

Electrical connector

16

Electrical connector

7

Bracket

12

Bolts

17

Fuel line

8

Screw

13

Bracket

 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

 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

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 the vacuum pump.

AR43.05-S-1320P

2

Remove screw (5).

 M6

*BA00.10-N-1002-01A

3

Remove fuel high-pressure pump.

AR07.02-S-1028PD

4

Remove fuel injectors.

AR07.16-S-1020PD

5

Remove timing chain.

AR05.10-S-7602PD

6

Remove screws (8).

 M8

*BA00.10-N-1003-01A

7

Position bracket (7) outside of the working area.

8

Disconnect electrical connector (15).

9

Separate electrical connection (16).

Model 470 with engine 699.304/305

10

Remove electrical wiring harness (6) from the cylinder head cover (2) and position outside of the working area.

11

Remove fuel line (17) from rail and position outside the working area.

Model 470 with engine 699.304/305

 Seal connections. Collect escaping fuel.

 Record plug

*129589009100

12

Remove fuel lines (9) from the cylinder head cover (2) and position outside of the working area.


Do not kink fuel lines (9).
Otherwise, damage to the fuel lines (9) may occur.

13

Position lines (10) outside the working area.


Do not kink lines (10).
Otherwise, damage to the lines (10) may occur.

14

Separate electrical connector (11).

15

Remove bracket (13).

 To do so, remove screws/bolts (12).

 M6

*BA00.10-N-1002-01A

16

Unscrew screw (14).

 M6

*BA00.10-N-1002-01A

17

Remove the bracket (3).

 For this purpose, remove bolts (4).

 M8

*BA00.10-N-1003-01A

18

Remove screws (1) in reverse order to the tightening procedure.

AR01.20-S-5014-03PD

 Observe cylinder head cover (2) tightening procedure.

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-N-1001-03PD

19

Remove cylinder head cover (2).

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

Notes on sealant path for cylinder head cover

AH01.30-N-1000-08US

 Removal: Carefully pry off cylinder head cover (2) using a suitable tool.

 Installation: Apply sealant according to the sealant path.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

20

Remove rail from cylinder head cover (2).

If cylinder head cover (2) will be replaced.

AR07.03-S-1010PD



Clean

21

Clean sealing surface on cylinder head cover (2).

If cylinder head cover (2) will not be replaced.

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surface will otherwise be damaged.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

22

Clean sealing surface at cylinder head.

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surface will otherwise be damaged.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

23

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

24

Check for leaktightness when engine is running.

 Visual inspection only.

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

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

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

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

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

Number

Designation

8.8

10.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

23

32

Phosphated

Nm

21

29

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

Number

Designation

12.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

38

Phosphated

Nm

36

 Cylinder head cover

Number

Designation

Engine 699 in model 470, 471

BA01.20-N-1001-03PD

Screw/bolt, cylinder head cover to cylinder head

Stage 1

Nm

5

Stage 2

Nm

15

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

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09