Remove/install cylinder head cover - AR01.20-P-5014GZB: Notes
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ENGINES 642 in MODEL 164
| Remove/install | |||
|---|---|---|---|
| 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 | |
| Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel jets or leakage. | Keep all ignition sources out of hazard area. Do not carry out any work on the system when it is pressurized. | AS07.16-Z-0001-01A | |
| Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof | Keep body parts and limbs well clear of moving parts. | AS00.00-Z-0011-01A | |
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| 1 | Removes strut tower brace | Model 164.8 only Remove strut tower brace from strut tower mounts. |
AR62.30-P-2500GY |
| 2 | Remove engine air intake duct downstream of air filter | AR09.10-P-8130GZB | |
| 3 | Remove engine charge air duct on turbocharger | AR09.41-P-8622GZB | |
| 4 | Remove exhaust gas recirculation positioner | When removing left cylinder head cover | AR14.20-P-1020GZB |
| 5 | Remove injectors | AR07.16-P-1000GZB | |
| 6 | Remove rail | AR07.03-P-1010GZB | |
| 7 | Remove power steering expansion reservoir | On left cylinder head cover. | |
| 8 | Detach fuel line (1) | On left cylinder head cover. The fuel line (1) must be removed with the flexible feed and return hose so that expansion reservoir for the power steering can be placed to one side. |
|
| 9 | Unscrew bracket (2) for vacuum line | On left cylinder head cover. | |
| *BA01.20-P-1003-01P | |||
| *BA01.20-P-1004-01P | |||
| 10 | Loosen cylinder head cover bolt in stages and remove | On left cylinder head cover. Slacken cylinder head bolts in the reverse sequence of the tightening procedure when the engine has cooled down so that the cylinder head cover is not warped. ↓ |
|
| Bolt tightening procedure for cylinder head cover | AR01.20-P-5014-03PI | ||
| Installation: Pay attention to the tightening procedure and the tightening instructions for the cylinder head bolts so that the cylinder head cover is not warped and the camshafts are not damaged. ↓ | |||
| Bolt tightening procedure for cylinder head cover | AR01.20-P-5014-03PI | ||
| *BA01.20-P-1001-01P | |||
| 11 | Remove left cylinder head cover | Detach left cylinder head cover with impact extractor and threaded stud, then remove. | |
| Notes on sealant path for cylinder head cover | AH01.30-P-1000-08PI | ||
| Fig 4 | |||
| Fig 3 | |||
| Loctite 5970 sealant | *BR00.45-Z-1013-01A | ||
| 12 | Remove vacuum pump | On right cylinder head cover. | AR43.05-P-1320GZ |
| 13 | Remove oil separator (4) from right cylinder head cover | Vehicles up to model year 2009 | |
| *BA01.20-P-1005-01P | |||
| 14 | Remove oil separator connection fittings (5) from right cylinder head cover | Vehicles up to model year 2009 Installation: Replace O-ring and radial shaft sealing ring. |
|
| 15 | Remove pressure differential sensor bracket (DPF) (7) from right cylinder head cover | Vehicles as of model year 2009 | |
| *BA07.04-P-1010-01G | |||
| 16 | Remove vent valve (6) | Vehicles as of model year 2009 Installation: Replace O-ring and radial shaft sealing ring. |
|
| 17 | Detach electrical connector from camshaft Hall sensor (B6/1) | On right cylinder head cover. | |
| 18 | Loosen cylinder head cover bolt in stages and remove | On right cylinder head cover. Loosen cylinder head cover bolts in reverse order of the tightening procedure on a cooled off engine so that the cylinder head cover does not shift, see: ↓ |
|
| Bolt tightening procedure for cylinder head cover | AR01.20-P-5014-03PI | ||
| Installation: Observe tightening procedure and tightening instructions for cylinder head cover bolts so that the cylinder head cover does not shift and leads to damage to the camshaft, see: ↓ | |||
| Bolt tightening procedure for cylinder head cover | AR01.20-P-5014-03PI | ||
| *BA01.20-P-1001-01P | |||
| 19 | Remove right cylinder head cover | Detach cylinder head cover using impact extractor and threaded studs, then remove. | |
| Fig 4 | |||
| Fig 3 | |||
| Loctite 5970 sealant | *BR00.45-Z-1013-01A | ||
| Clean | |||
| 20 | Clean sealing surface on cylinder head covers and cylinder heads | Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces. | AR01.00-P-0050-01A |
| Loctite 7200 | *BR00.45-Z-1038-04A | ||
| Loctite 7063 cleaning spray (150 ml) | *BR00.45-Z-1046-04A | ||
| 21 | Install in the reverse order | ||
| Checking | |||
| 22 | Check engine oil level | In order to avoid measurement errors, vehicle must be parked on an even surface. Inspect engine oil level about 5 min. after switching off warm engine |
AR18.00-P-3035-01PI |
| *BF18.00-P-1001-01A | |||
| *BF18.00-P-1001-01S | |||
| 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 | |
| 23 | Check for oil leaks with engine running | ||
| 24 | Check fuel system for leaks with engine running |
CRANKCASE VENTILATION, CYLINDER HEAD COVER
| Number | Designation | Engine 642 | ||
|---|---|---|---|---|
| BA01.20-P-1001-01P | Bolt, cylinder head cover to cylinder head | Stage 1, apply | Nm | 4 |
| Stage 2, initial torque | Nm | 6 | ||
| Stage 3, final torque | Nm | 9 | ||
| BA01.20-P-1003-01P | Bolt, bracket to cylinder head | M6X12 | Nm | 9 |
| BA01.20-P-1004-01P | Bolt, bracket to cylinder head cover | M6X12 | Nm | 9 |
| BA01.20-P-1005-01P | Bolt connecting oil separator to cylinder head cover | Nm | 14 | |
SENSORS
| Number | Designation | Engine 642 with particle filter | |
|---|---|---|---|
| BA07.04-P-1010-01G | Bolt, pressure differential sensor bracket to cylinder head cover and cylinder head | Nm | 14 |
ENGINE LUBRICATION SYSTEM
| Number | Designation | Engine 642 without particulate filter | ||
|---|---|---|---|---|
| BF18.00-P-1001-01A | Engine oil | Filling capacity (oil and filter change) |
Liters | 8.5 |
| Specifications for Operating Fluids | Sheet | BB00.40-P-0228-03A | ||
| Sheet | BB00.40-P-0228-05A | |||
| Sheet | BB00.40-P-0228-51A | |||
| Sheet | BB00.40-P-0229-03A | |||
| Sheet | BB00.40-P-0229-31A | |||
| Sheet | BB00.40-P-0229-05A | |||
| Sheet | BB00.40-P-0229-51A | |||
ENGINE LUBRICATION SYSTEM
| Number | Designation | Engine 642 with particulate filter | ||
|---|---|---|---|---|
| BF18.00-P-1001-01S | Engine oil | Filling capacity (oil and filter change) |
Liters | 8.5 |
| Specifications for Operating Fluids | Sheet | BB00.40-P-0228-51A | ||
| Sheet | BB00.40-P-0229-31A | |||
| Sheet | BB00.40-P-0229-51A | |||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1013-01A | Loctite sealant 5970 | A 003 989 98 20 |
| BR00.45-Z-1038-04A | Loctite 7200 | Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925 Munchen Germany Tel. +49 899268-0 Fax + 49 899101978 www.Loctite.de |
| BR00.45-Z-1046-04A | Cleaning spray, Loctite 7063 (150ml) | A 001 986 71 71 10 |