Remove/install front cap on cylinder head

AR01.30-P-5700MRM

Remove/install front cap on cylinder head

12.03.2020

Engine

274.9 in model 167

1

Charge air pipe

2

Vent line

3

Cover at front

4

Charge air cooler

5

Screws (9 ea.)

6

Bolts

7

Bracket

Y49/1

Intake camshaft solenoid

Y49/2

Exhaust camshaft solenoid

 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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove upper engine cover.



AP01.10-P-2405-01O

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

2

Remove engine air intake duct upstream of air filter.

3

Unscrew cap from coolant expansion reservoir and release pressure in engine cooling system.

4

Remove charge air pipe (1).

 Charge air pipe/charge air cooling

*BA09.41-P-1001-01U

5

Remove bleed line (2) from front cover (3).

 Screw, full load bleed line to chain case cover

*BA01.20-P-1011-01R

6

Remove charge air cooler (4) and place to one side with connected coolant lines.

AR09.41-P-0105MRM

7

Release and disconnect electrical connector of intake camshaft solenoid (Y49/1) and exhaust camshaft solenoid (Y49/2).

8

Remove oil filter cover.

 Threaded cap to oil filter housing

*BA18.20-P-1001-01I

9

Remove bolts (5) at front cover (3).

 Bolt, front cover to cylinder head/cylinder head cover

*BA01.30-P-1003-01Y

10

Detach front cover (3) and remove.

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

Notes on sealant path for front cover to cylinder head xxx

AH01.30-P-1000-02MR


During removal, do not drive in any tool between front cover (3), cylinder head cover and cylinder head.
Sealing surfaces will otherwise be damaged.

 Installation: Apply sealant to front cover (3).

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

11

Remove intake camshaft solenoid (Y49/1) and exhaust camshaft solenoid (Y49/2).

When replacing front cover (3).

Remove/install intake camshaft adjustment solenoid

AR05.20-P-7305MRK

Remove/install exhaust camshaft adjustment solenoid

AR05.20-P-7306MRK

12

Unscrew bolts (6) and remove bracket (7).

When replacing front cover (3).

 Screw, water-cooled charge air cooler holder to cylinder head cover/cylinder head/chain case cover

*BA09.41-P-1003-01U



Clean

13

Thoroughly clean sealing surfaces of front cover (3), cylinder head and cylinder head cover.

AR01.00-P-0050-01A

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

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A



Check

14

Check sealing surfaces of front cover (3), cylinder head and cylinder head cover for damage.

If there is a problem,



Replace corresponding component.

Remove/install cylinder head

AR01.30-P-5800MRM

 Replace cylinder head cover and cylinder head together as both component parts form a unit.

15

Install in the reverse order.



Check

16

Check engine oil level in multifunction display and correct if necessary.



AP18.00-P-1812SKI

 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

17

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

 Crankcase ventilation system, cylinder head cover, camshaft housing

Number

Designation

Engine 274

BA01.20-P-1011-01R

Screw, full load bleed line to chain case cover

Nm

8

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1003-01Y

Bolt, front cover to cylinder head/cylinder head cover

M6

Nm

9

M8

Nm

-

 Charge air pipe/charge air cooling

Number

Designation

Engine 274

BA09.41-P-1001-01U

Charge air pipe/charge air cooling

Nm

9

 Charge air pipe/charge air cooling

Number

Designation

Engine 274

BA09.41-P-1003-01U

Screw, water-cooled charge air cooler holder to cylinder head cover/cylinder head/chain case cover

Nm

8

 Oil filter

Number

Designation

Engine 274

BA18.20-P-1001-01I

Threaded cap to oil filter housing

Nm

25

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