Remove/install cylinder head cover

AR01.20-P-5014MRM

Remove/install cylinder head cover

12.03.2020

Engine

274.9 in model 167

Modification notes

30.01.2020

Water-cooled charge air cooler bracket screw at cylinder head cover/cylinder head/chain case cover

BA09.41-P-1003-01U

1

Charge air cooler

3

Cover at front

4

Rail

5

Air cleaner housing

6

Oil separator

7

Cylinder head cover

8

Vent line

9

Ball stud

10

Engine suspension lug

11

Vacuum pump

12

Cap

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 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 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

 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

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

 

Remove/install

1

Drain off coolant.

AR20.00-P-1142MRM

 Installation: Only install lower engine compartment paneling after leak test.

2

Remove the charge air cooler (1).

AR09.41-P-0105MRM

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

3

Remove bracket of charge air cooler (1).

 Bolt, holder for engine mount to holder for charge air cooler

*BA09.41-P-1004-01U

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

*BA09.41-P-1003-01U

4

Disconnect and remove engine wiring harness in area of cylinder head cover (7).

AR15.18-P-1000-04MRM

 Screw, engine cable duct to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding

*BA01.20-P-1010-01R

5

Remove front cover (3) at cylinder head.

AR01.30-P-5700MRM

6

Remove fuel high-pressure pump.

AR07.02-P-1028MRM

7

Remove rail (4) with fuel injectors.

AR07.03-P-1052MRM

8

Remove air filter housing (5).

AR09.10-P-1150MRM

9

Remove front bracket of air filter housing (5).

 Bolt, front air filter housing holder to cylinder head/cylinder head cover

*BA01.30-P-1009-01Y

10

Remove right rear engine lifting lug (10) and place to one side.

 Bolt, lifting eye to cylinder head/cylinder head cover

*BA01.30-P-1008-01Y

11

Remove ignition coils.

AR15.12-P-2003MRM

12

Remove oil separator (6) from cylinder head cover (7) and place to one side.

AR01.20-P-9691MRM

13

Remove bleed line (8) from cylinder head cover (7) and place to one side.

 Hose clamp pliers

*454589003700

14

Remove vacuum pump (11).

AR43.05-P-1320MRM

15

Remove cap (12).

 Installation: Replace cap (12).

16

Release bolts of cylinder head cover (7) in reverse order to tightening procedure and remove.

Tightening procedure

AR01.20-P-5014-03MR

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Installation: Replace screw/bolts.
Observe tightening procedure for cylinder head cover (7).

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-P-1001-01R

17

Remove cylinder head cover (7) from cylinder head.

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-P-1000-08MM


During removal, do not drive in any tool between cylinder head cover (7) and cylinder head.
Sealing surfaces will otherwise be damaged.

 Installation: Install new sealing rings.
Apply sealant to cylinder head cover (7).

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

18

Remove ball pin (9).

When replacing the cylinder head cover (7).

19

Remove position sensors of camshafts.

When replacing the cylinder head cover (7).

Remove/install position sensor of intake camshaft

AR07.04-P-0056MRK

Remove/install position sensor of exhaust camshaft

AR07.04-P-0057MRK

20

Remove top slide rail.

When replacing the cylinder head cover (7).

AR05.10-P-8480MRM

21

Remove oil filler cap with molded seal.

When replacing the cylinder head cover (7).



Check

22

Check upper slide rail of timing chain for galling and score marks.

If there is a problem:



Replace upper slide rail.

AR05.10-P-8480MRM

23

Check sealing surfaces of cylinder head cover (7) and cylinder head for damage.

If there is a problem:



Replace cylinder head cover (7) and cylinder head.

Remove/install cylinder head

AR01.30-P-5800MRM

 Replace cylinder head cover (7) and cylinder head together as both component parts form a unit.

24

Check camshaft bearing points in cylinder head cover (7), cylinder head and at camshafts for galling and score marks.

General information on checking camshafts and bearing points of camshafts

AH05.20-P-1000-09SZ

If there is a problem,



replace cylinder head cover (7), cylinder head and camshafts.

Remove/install cylinder head

AR01.30-P-5800MRM

Remove/install camshafts

AR05.20-P-6992MRK



Clean

25

Clean sealing surfaces of cylinder head and cylinder head cover (7).

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
Sealing surfaces will otherwise be damaged.

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

Loctite 7200

*BR00.45-Z-1038-04A

26

Install in the reverse order.

 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

27

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-1001-01R

Screw/bolt, cylinder head cover to cylinder head

Stage 1

Nm

10

Stage 2

°

90

 Crankcase ventilation system, cylinder head cover, camshaft housing

Number

Designation

Engine 274

BA01.20-P-1010-01R

Screw, engine cable duct to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding

Nm

8

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1008-01Y

Bolt, lifting eye to cylinder head/cylinder head cover

M8

Nm

20

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1009-01Y

Bolt, front air filter housing holder to cylinder head/cylinder head cover

M8

Nm

20

 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

 Charge air pipe/charge air cooling

Number

Designation

Engine 274

BA09.41-P-1004-01U

Bolt, holder for engine mount to holder for charge air cooler

Nm

20

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