Remove/install cylinder head cover

AR01.20-P-5014PM

Remove/install cylinder head cover

22.10.09

25.9.03

Value changed from 11 Nm to 23 Nm

Value in series 1007 changed for engine 646.962/963

*BA07.16-P-1007-01D



Removing

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove trim panel of cylinder head cover (1)

AR01.20-P-5014-02A

2

Remove air filter housing

AR09.10-P-1150PM

3

Remove heat shield

AR49.00-P-1000-01T

4

Disconnect electrical connector at camshaft Hall sensor (B6/1)

5

Remove injection lines

6

Remove injectors

AR07.16-P-1000T



Notes on injectors

AH07.16-P-1000-01A

7

Detach engine wiring harness duct from cylinder head cover (1) and place to the side

8

Remove cylinder head cover (1)

 Installation: Replace seals (2, 3) on cylinder head cover (1) to avoid leaks.



Install

9

Fit on cylinder head cover (1)

 Do not tighten bolts, as the injectors are aligned through the cylinder head cover (1). Otherwise there may be gas leakage or seizing up of the injectors due to combustion residues in the cylinder head, or impermissible voltages in the injection lines.

10

Install injectors

 To mount injection lines free of tension, injection lines must be placed before tightening the injectors.

AR07.16-P-1000T



Notes on injectors

AH07.16-P-1000-01A

11

Tighten bolts on cylinder head cover (1)

 Bolt connecting cylinder head cover to cylinder head

*BA01.20-P-1001-01G

12

Install engine wiring harness duct

 Injection lines must be taken off to install the cable duct.

13

Install injection lines

 To prevent leakage, observe the exact location of the injection lines. Check the sealing cones at the injection lines, and replace injection lines if pressure marks are visible.

 Nut, pressure line to rail/injector

*BA07.16-P-1007-01D

14

Put electrical connector onto camshaft Hall sensor (B6/1)

15

Install heat shield

AR49.00-P-1000-01T

16

Install air filter housing

AR09.10-P-1150PM

17

Check for oil leaks with engine running

 Danger!

Risk of explosion from 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 systems when they are under pressure

AS07.16-Z-0001-01A

18

Check fuel system for leaks with engine running

19

Install trim panel of cylinder head cover (1)

AR01.20-P-5014-02A

Number

Designation

Engine
646.962/963/966

BA01.20-P-1001-01G

Bolt, cylinder head cover to cylinder head

Nm

9

Number

Designation

Engine
646.962/
963/966

BA07.16-P-1007-01D

Nut, pressure line to rail/injector

Stage 1

Nm

23

Stage 2

Nm

-