Remove/install right cylinder head cover

AR01.20-S-5012PS

Remove/install right cylinder head cover

18.02.2020

Engine

642 in model 470, 471

Modification notes

10.07.2019

Engine oil

BF18.00-N-1001-01PS

20.11.2019

Method extended

Operation step 4

20.11.2019

Special tool 112 589 00 25 00 squeeze gun added

Step 9

1

Cylinder head cover

3

Bracket

5

Coolant line

2

Oil separator

4

Nuts

11

Screw

 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

 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

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove right rail.

AR07.03-S-1012PS

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

2

Remove all fuel injectors of right cylinder bank.

AR07.16-S-1020PS

3

Remove oil separator (2).

AR01.20-S-9750PS

4

Remove bracket (3).

 To do this, remove nuts (4) and place bracket (3) to one side.

 M6

*BA00.10-N-1002-01A

5

Disconnect engine wiring harness in the area of the cylinder head cover (1) and expose.

6

Remove coolant line (5) from the cylinder head cover (1) and place to one side with connected coolant hoses.

 Screw/bolt, bracket to cylinder head cover

*BA01.20-N-1004-01O

7

Remove the vacuum pump.

AR43.05-S-1320PS

8

Remove all screws (11) in stages in reverse order of the tightening procedure of the cylinder head cover (1).

AR01.20-S-5014-03SE


Observe tightening procedure when loosening and tightening the screws (11).
Otherwise, damage to the cylinder head cover (1) will occur.

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-N-1001-01O

9

Loosen cylinder head cover (1) with the impact extractor and remove.

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-1000-08SE

 Installation: Apply sealant as per the sealant path.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Threaded bolt

*102589003400

 Application gun

*112589002500

 Impact extractor

*116589203300



Clean

10

Clean sealing surfaces on the cylinder head cover (1).

If a new cylinder head cover (1) is not installed.

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

11

Clean sealing surface at cylinder head.

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

12

Change position sensor of the camshaft.

If a new cylinder head cover (1) is installed.

AR07.04-S-0058PS

13

Change engine oil filler neck.

If a new cylinder head cover (1) is installed.

14

Install in the reverse order.



Check

15

Check engine oil level.


The engine oil level must not be above the maximum marking.
Otherwise engine damage may occur.

If engine oil level is incorrect,



Correct engine oil level.

 Engine oil

*BF18.00-N-1001-01PS

 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

16

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

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 642 in model 470, 471

BA01.20-N-1001-01O

Screw/bolt, cylinder head cover to cylinder head

Stage 1, apply

Nm

4

Stage 2, initial torque

Nm

6

Stage 3, final torque

Nm

8

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 642 in model 470, 471

BA01.20-N-1004-01O

Screw/bolt, bracket to cylinder head cover

M6x12

Nm

9

 Filling capacities for engine lubrication system

Number

Designation

Engine 642 in model 470, 471

BF18.00-N-1001-01PS

Engine oil

Filling capacity (oil and filter change)

Liter

8,5

Sheet

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-51A

Sheet

BB00.40-P-0229-52A

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