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Remove/Install Cylinder Head Cover - AR01.20-P-5014MRA

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Engine 274.9 in model 205 

Engine 274.9 in model 253 

MODIFICATION NOTES

06.05.2021 Check camshafts and camshaft bearing points in cylinder head cover (6) and the cylinder head for galling and scoring. Operation step 27.  

Shown on engine 274.910 in model 205 

Fig 1: Cylinder Head Cover Components Location - Engine 274.9 In Model 253 (Shown On Engine 274.910 In Model 205)
G14547523Courtesy of MERCEDES-BENZ USA
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 contact with 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.  Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
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
CAUTION Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning  caused by swallowing engine oil Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.		 AS18.00-Z-0001-01A
Notice  Information on preventing damage to electronic components due to 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 work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVINGINSTALLING Remove/install     
1 Drain off coolant.   AR20.00-P-1142LW
    INSTALLATION IMPORTANT Only install upper engine cover and lower engine compartment paneling after the performing a leak test.  
2 Remove charge air cooler.   AR09.41-P-6819MRA
3 Place coolant bleed line (5) to one side.    
4 Remove ME-SFI [ME] control unit (N3/10).   AR07.08-P-7008MRA
5 Remove bracket of the charge air cooler. TORQUE SPECIFICATION Screw, water-cooled charge air cooler holder to cylinder head cover/cylinder head/chain case cover *BA09.41-P-1003-01U 
6 Remove front cover (9).   AR01.30-P-5700MRB
7 Remove high-pressure fuel pump (3).   AR07.02-P-1020MRA
8 Remove rail (10) with fuel injectors.   AR07.03-P-1052MRA
9 Remove air filter housing (1).   AR09.10-P-1150MRA
10 Remove front bracket of the air filter housing (1). TORQUE SPECIFICATION M8X1.25 *BA00.10-P-1005-04A 
11 Remove rear right engine lifting lug and place to one side. TORQUE SPECIFICATION Bolt, lifting eye to cylinder head/cylinder head cover *BA01.30-P-1008-01Y 
12 Remove ignition coils.   AR15.12-P-2003MRA
13 Remove the intake camshaft valve lift changeover actuator (Y49/8). Engine 274.910 in model 205 AR05.20-P-6500MRA
14 Remove oil separator (4) from the cylinder head cover (6) and place to one side. Engine 274.9 in model 205 with code 494 (US version)
Engine 274.9 in model 205 with code 945 (China Stage 6 exhaust treatment)
Engine 274.9 in model 253 with code 494 (US version)
Engine 274.9 in model 253
with code 945 (China Stage 6 exhaust treatment)		 AR01.20-P-9691MRU 
    Engine 274.9 in model 205 except code 494 (US version) except code 945 (China Stage 6 exhaust treatment)
Engine 274.9 in model 253 except code 494 (US version)
except code 945 (China Stage 6 exhaust treatment)		 AR01.20-P-9691MRA 
15 Remove coolant bleed line (11) from the cylinder head cover (6), unclip from the brackets, and place to one side. SPECIAL TOOL Hose clamp pliers Fig 2
16 Disconnect engine wiring harness. TORQUE SPECIFICATION M6X1 AR15.18-P-1000-04LWA
*BA00.10-P-1002-04A 
17 Remove the vacuum pump.   AR43.05-P-1320LWA
18 Remove cap (2). INSTALLATION IMPORTANT Replace cap (2).  
19 Release bolts of cylinder head cover (6) in reverse order to tightening procedure and remove. INSTALLATION IMPORTANT Replace screw/bolts.
Observe tightening procedure for cylinder head cover (6).		 AR01.20-P-5014-03MR 
    TORQUE SPECIFICATION Screw/bolt, cylinder head cover to cylinder head *BA01.20-P-1001-01R 
20 Remove cylinder head cover (6) from the cylinder head.    
  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-P-1000-08MM 
    NOTES Do not hammer in a tool to pry off between cylinder head cover (6) and cylinder head.
Sealing surfaces of cylinder head and cylinder head cover (6) will otherwise be damaged.
IMPORTANT Cylinder head cover (6) and cylinder head must be replaced together.
INSTALLATION IMPORTANT Install new sealing rings.
INSTALLATION IMPORTANT Apply sealant to cylinder head cover (6).		  
    Sealant, Loctite 5970, 50 ml *BR00.45-Z-1013-01A 
    SPECIAL TOOL Application gun Fig 3
21 Remove brackets (7) of the engine cover. When replacing cylinder head cover (6).  
22 Remove bracket for air intake pipe. When replacing cylinder head cover (6).  
23 Remove Hall sensors of the camshafts. When replacing cylinder head cover (6). AR15.10-P-2000MRA
24 Remove top slide rail (8). When replacing cylinder head cover (6). AR05.10-P-8480MRA
25 Remove oil filler cap with molded seal. When replacing cylinder head cover (6).  
INSPECT Check     
26 Check top slide rail (8) of the timing chain for galling and score marks. If galling or score marks are present,
↓
Replace upper slide rail (8).		 AR05.10-P-8480MRA
27 Check camshafts and camshaft bearing points in cylinder head cover (6) and the cylinder head for galling and scoring.
General information on checking camshafts and bearing points of camshafts		   AH05.20-P-1000-09SZ
    IMPORTANT Cylinder head cover (6) and cylinder head form a unit and can thus only be replaced together.
IMPORTANT The cylinder head can also be replaced without replacing the camshaft.
If there are problems,
↓
Replace camshafts and/or cylinder head cover (6) together with cylinder head.		  
    Replace cylinder head AR01.30-P-5800MRB
    Replace camshafts AR05.20-P-6992MRA
CLEAN Clean     
28 Clean sealing surfaces on cylinder head and cylinder head cover (6). NOTES Do not use any sharp-edged tools or abrasive paper.
Sealing surfaces of cylinder head and cylinder head cover (6) will otherwise 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.    
WARNING 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 safety glasses.
Use the extraction system. Move people out of the danger zone.		 AS49.00-Z-0001-01A
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
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 M6X1 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 M8X1.25 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
Fig 2: Identifying Hose Clamp Pliers (003 589 03 37 00)
G13744653Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Application Gun (112 589 00 25 00)
G13655248Courtesy of MERCEDES-BENZ USA
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 A 010 989 90 71
BR00.45-Z-1046-04A Loctite 7063 (400 ml) cleaning spray A 001 986 71 71 09
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