Remove/install front cover on cylinder head - AR01.30-P-5700QK

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ENGINE 271.940 in MODELS 203.042 /242 /742, 209.342 /442

ENGINE 271.941 in MODELS 211.042 /242

ENGINE 271.946 in MODELS 203.046 /246 /746

ENGINE 271.948 in MODELS 203.040 /240 /740

ENGINE 271.942 in MODELS 203.043 /243 /743, 209.343

ENGINE 271.921 in MODEL 203.730

ENGINE 271.955 in MODELS 209.341 /441

ENGINE 271.956 in MODELS 211.041 /241

Shown on engine 271.940

Fig 1: Identifying Front Cover On Cylinder Head Remove/Install Components - Shown On Engine 271.940

MODIFICATION NOTES

1.3.04

Disconnect/connect ground line on battery

	Remove/install
1	Open engine hood	Model 203	AR88.40-P-1000P
		Model 209	AR88.40-P-1000Q
		Model 211	AR88.40-P-1000T
2	Remove cover (6)
3	Remove exhaust gas recirculation valve	Engine 271.942	AR14.20-P-7662D
4	Disconnect electrical connectors at camshaft exhaust solenoid (Y49/3) and camshaft intake solenoid (Y49/1)
5	Slacken poly-V-belt (2)	To do this, swing Torx recess clearance under tensioning pulley in counterclockwise direction, see:
		See Remove/install poly-V-belt.	AR13.22-P-1202QK
6	Remove the guide pulley (1) of the poly-V-belt (2)		*BA01.40-P-1001-01K
7	Remove cylinder head cover	Engines 271.921/940/942/946/948/955	AR01.20-P-5014QK
		Engine 271.941/956	AR01.20-P-5014TK
8	Drain coolant from radiator	Model 203, 209	AR20.00-P-1142PR
		Model 211	AR20.00-P-1142T
9	Remove housing of coolant thermostat (3), unscrew bolts (3a) for this purpose	Installation: Replace O-ring.
			*BA01.30-P-1009-01J
10	Remove lifting eye (5) at cylinder head		*BA01.30-P-1005-01J
			*BA01.30-P-1006-01J
11	Remove cover (4) at cylinder head	Installation: Clean sealing surfaces. Coat sealing surface of cover (4) to cylinder head with sealant.
			*BA01.30-P-1007-01J
		Sealant	*BR00.45-Z-1013-01A
12	Install in the reverse order

CYLINDER HEAD

Number	Designation			Engine 271
BA01.30-P-1005-01J	Bolt connecting suspension lug to cylinder head	M8	Nm	20
BA01.30-P-1006-01J	Bolt, lifting eye to front cover	M6	Nm	9
BA01.30-P-1007-01J	Bolt, front cover to cylinder head	M6	Nm	9
BA01.30-P-1009-01J	Bolt, thermostat housing to cylinder head	M6	Nm	9

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation		Engine 271
BA01.40-P-1001-01K	Bolt, guide pulley to timing case	Nm	20

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Sealant	A 003 989 98 20