Remove/Install Cylinder Head Cover - AR01.20-P-5014MRD
Engine 274.9 in Model 213
Engine 274.9 in Model 238
MODIFICATION NOTES
| 06.05.2021 | Check the camshafts and cam bearing points in the cylinder head cover (6) and the cylinder head for traces of wear and scoring. | Operation step 27. |
Shown on engine 274.910 in model 213
| Risk of explosion caused by fuel igniting. Risk of poisoning through inhalation and swallowing fuel and Risk of injury to skin and eye caused by contact with fuel | Fire, sparks, open flames and smoking are prohibited. Only fill fuel in suitable and appropriately labeled containers. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| Risk of injury to skin and eyes from handling hot or glowing objects | Wear protective gloves, protective clothing and, if necessary, protective goggles. | AS00.00-Z-0002-01A | |
| Risk of injury from cuts or scrapes on sharp-edged vehicle parts | Always wear protective gloves when working on or in the area of sharp, unburred vehicle parts. Deburr the repair panels. |
AS00.00-Z-0017-01A | |
| Risk of injury to skin and eyes from handling engine oil. Risk of poisoning by swallowing engine oil | Wear protective gloves, protective clothing and protective goggles. Do not fill engine oil into drinking containers. |
AS18.00-Z-0001-01A | |
| NOTICE | Notes on avoiding damage to electronic components through electrostatic discharge | AH54.00-P-0001-01A | |
| NOTICE | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| NOTICE | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| NOTICE | Notes on threaded connections with aluminum screws/bolts | AH00.00-P-0006-01RM | |
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| General information on working on gasoline direct fuel injection | AH07.00-P-2000-01A | ||
| Remove/Install | |||
| 1 | Drain off coolant. | AR20.00-P-1142OLC | |
| 2 | Remove soundproofing. | Engine 274.9 in Model 213 except code 920 (direct fuel injection with stratified charge) Engine 274.9 in Model 238 except code 920 (direct fuel injection with stratified charge) |
AR94.30-P-5410MRD |
| 3 | Place coolant bleed line (5) to one side. | ||
| 4 | Remove charge air cooler. | AR09.41-P-0105MRD | |
| 5 | Remove ME-SFI [ME] control unit (N3/10). | AR07.08-P-7013MRD | |
| 6 | Remove bracket of the charge air cooler. | *BA09.41-P-1003-01U | |
| 7 | Remove front cover (9). | AR01.30-P-5700MRD | |
| 8 | Remove high pressure fuel pump (3). | AR07.02-P-1028MRD | |
| 9 | Remove the rail (10) with fuel injectors. | AR07.03-P-1052MRD | |
| 10 | Remove the air filter housing (1). | AR09.10-P-1150MRD | |
| 11 | Remove the front bracket of the air filter housing (1). | *BA00.10-P-1005-04A | |
| 12 | Remove rear right engine mounting bracket and put it to one side. | *BA01.30-P-1008-01Y | |
| 13 | Remove ignition coils. | AR15.12-P-2003MRD | |
| 14 | Remove the valve lift switch actuator. | Engine 274.910 in Model 213 | AR05.20-P-6500MRA |
| 15 | Remove the oil separator (4) from the cylinder head cover (6) and put it to one side. | Engine 274.9 in Model 213 except for code 494 (USA version) except for code 945 (China Stage 6 exhaust gas cleaning) Engine 274.9 in Model 238 except for code 945 (China Stage 6 exhaust gas cleaning) |
AR01.20-P-9691MRD |
| Engine 274.9 in Model 213 with code 494 (USA version) |
AR01.20-P-9691MRU | ||
| 16 | Remove coolant bleed line (11) from cylinder head cover (6), unclip from the brackets and place to one side. | Fig 2 | |
| 17 | Disconnect engine wiring harness. | AR15.18-P-1000-04MRD | |
| *BA00.10-P-1002-04A | |||
| 18 | Remove vacuum pump. | AR43.05-P-1320MRD | |
| 19 | Remove cap (2). | ||
| 20 | Loosen and remove the bolts on the cylinder head cover (6) in the reverse order of the tightening diagram. | AR01.20-P-5014-03MR | |
| *BA01.20-P-1001-01R | |||
| 21 | Remove the cylinder head cover (6) from the cylinder head. Notes for applying surface sealants to seal assemblies |
AH00.00-P-0500-01MNE | |
| Notes on sealant path for cylinder head cover | Do not hammer in a tool to pry off between cylinder head cover (6) and cylinder head. Otherwise, damage to the sealing surfaces can occur. |
AH01.30-P-1000-08MM | |
| Sealant, Loctite 5970, 50 ml | *BR00.45-Z-1013-01A | ||
| Fig 3 | |||
| 22 | Remove the brackets (7) from the engine cover. | When installing the cylinder head cover (6). | |
| 23 | Remove the hall sensors from the camshafts. | When installing new cylinder head cover (6). | AR15.10-P-1999MRD |
| 24 | Remove the upper slide rail (8). | When installing new cylinder head cover (6). | AR05.10-P-8480MRD |
| 25 | Remove the oil filler cap with molded seal. | When installing new cylinder head cover (6). | |
| Check | |||
| 26 | Check the upper slide rail (8) of the timing chain for tracks and grooves. | If there are run-in marks and grooves, ↓ Replace the upper slide rail (8). |
AR05.10-P-8480MRD |
| 27 | Check camshafts and cam bearing points in the cylinder head cover (6) and the cylinder head for run-in marks and scoring. General information on checking camshafts and camshaft bearing points |
If there are problems, ↓ Replace camshafts and/or cylinder head cover (6) together with cylinder head. |
AH05.20-P-1000-09SZ |
| Replace cylinder head | AR01.30-P-5800MRD | ||
| Replace camshafts | AR05.20-P-6992MRD | ||
| Clean | |||
| 28 | Clean sealing surfaces on cylinder head and cylinder head cover (6). | Do not use any sharp-edged tools or sandpaper. Otherwise the sealing surfaces will be damaged. |
AR01.00-P-0050-01A |
| Loctite 7063 (400 ml) Cleaning spray | *BR00.45-Z-1046-04A | ||
| Loctite 7200 | *BR00.45-Z-1038-04A | ||
| 29 | Install in the reverse order. | ||
| Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and goggles. Use suction. Remove people from the hazard area. | AS49.00-Z-0001-01A | |
| Risk of accident due to automatic starting when the engine is running. Risk of injury from bruises and burns when intervening during the starting process or while the engine is running | Secure the vehicle against starting by itself. Wear closed, close-fitting work clothing. Do not touch hot or rotating parts. | AS00.00-Z-0005-01A | |
| 30 | Carry out engine test run and check engine for proper operation and leak tightness. |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1002-04A | M6 X 1 | Nm | 9 | 13 |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1005-04A | M8 X 1, 25 | Nm | 22 | 32 |
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 | ||
CYLINDER HEAD
| Number | Designation | Engine 274 | ||
|---|---|---|---|---|
| BA01.30-P-1008-01Y | Bolt, lifting eye 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 |
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 |