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

Engine 139 in model 118, 177, 247

MODIFICATION NOTES

29.03.2023	Special tools, added.	Operation step 20.
15.03.2023	New operation steps added.	Operation steps 1, 5, 19, 40, 43.

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	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
	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
	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
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 coolant		AH20.00-P-2080-01KOA
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove
1	Disconnect ground line from battery.	When the engine is switched off, the exhaust camshaft is positioned on the performance cams. The cylinder head cover must not be removed in this position.	AR54.10-P-0003MFA
2	Remove upper engine cover.
			AP01.10-P-2405-01K
3	Drain off coolant.		AR20.00-P-1142MFG
4	Remove rear cover at cylinder head.		AR01.30-P-5702MFG
5	Remove lift solenoids of exhaust camshaft.		AR05.20-P-6558MFG
6	Remove ignition coils.		AR15.12-P-2003MFG
7	Remove oil feed line of exhaust gas turbocharger.		AR09.40-P-6022MFG
8	Remove coolant feed line for exhaust gas turbocharger.		AR20.20-P-1000MFG
9	Unscrew bolts (2) and place cable duct (3) with connected lines as far as possible outside the working area.	Do not kink, subject lines to tension. Otherwise damage will occur.
10	Unscrew screw (4).
11	Unclip cable bracket (5) from cylinder head cover (1) and place as far as possible to one side.
12	Unscrew bolts (6), remove bleed line (7) and seal with suitable protective covers.	Set of protective covers	Fig 3
13	Remove cable bracket (14) from cylinder head cover (1).
14	Remove fuel injectors.		AR07.03-P-0004MFG
15	Release and disconnect electrical connectors (8).
16	Unscrew bolts (9) and release low-pressure line (10) from cylinder head cover (1).
17	Unscrew bolts (11) and release bleed line (12) from cylinder head cover (1).
18	Remove right engine mount.		AR22.10-P-1102MFG
19	Rotate engine on center bolt of crankshaft and set engine to ignition TDC.		AR01.10-P-1000-01MFG
		Counterholder	Fig 2
20	Position camshaft for removal of cylinder head cover (1).		AR05.20-P-6991-01MFG
		Adjustment tool	Fig 4
		Counterholder	Fig 2
21	Unscrew bolts (13) of cylinder head cover (1) in reverse order to the tightening procedure and remove cylinder head cover (1).	Bolt tightening procedure for cylinder head cover To remove, do not drive in any tool between cylinder head cover (1) and cylinder head. Sealing surfaces will otherwise be damaged.	AR01.20-P-5014-03MFG
	Check
22	Check position of performance cams (21).	P Performance cams (21) must be in position (A). Cylinder head cover (1), exhaust camshaft and cylinder head will otherwise be damaged. If performance cams (21) are in position (A): ↓ Follow the further repair process. If performance cams (21) are in position (B): ↓ Remove exhaust camshaft and correct position of performance cams (21). Remove/install camshafts	AR05.20-P-6992MFG
23	Check sealing surfaces of cylinder head cover (1) and cylinder head for damage.	If damage is found: ↓ Replace cylinder head cover (1) or cylinder head. Remove/install cylinder head	AR01.30-P-5800MFG
	Clean
24	Clean sealing surfaces of cylinder head cover (1) and cylinder head.		AR01.00-P-0050-01A
		Do not use any sharp-edged tools or abrasive paper. The sealing surfaces can be damaged otherwise. Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 (400 ml) cleaning spray	*BR00.45-Z-1046-04A
	Install
25	Apply sealant to cylinder head cover (1). Notes on sealant path for cylinder head cover		AH01.30-P-1000-08MM
	Notes on application of flange sealants to seal major assemblies		AH00.00-P-0500-01MNE
		Sealant, Loctite 5970, 50 ml	*BR00.45-Z-1013-01A
		Application gun	Fig 1
26	Install cylinder head cover (1) and screw in bolts (13).	Bolt tightening procedure for cylinder head cover	AR01.20-P-5014-03MFG
		Screw/bolt, cylinder head cover to cylinder head If cylinder head cover (1) must be replaced: ↓ Transfer position sensors of camshafts	*BA01.20-P-1001-01R
		Position sensor of the exhaust camshaft	AR07.04-P-0057MFG
		Position sensor of intake camshaft	AR07.04-P-0056MFG
27	Install right engine mount.		AR22.10-P-1102MFG
28	Attach bleed line (12) to cylinder head cover (1) and tighten bolts (11).	Screw, bleed line for crankcase ventilation system to crankcase/timing case cover/oil separator/cylinder head cover	*BA01.20-P-1005-01R
29	Attach low-pressure line (10) to cylinder head cover (1) and screw in bolts (9).	Bolt, coolant line to cylinder head cover	*BA01.20-P-1009-01R
30	Connect and lock electrical connectors (8).
31	Install fuel injectors.		AR07.03-P-0004MFG
32	Attach cable bracket (14) of cylinder head cover (1).
33	Remove protective covers, install bleed line (7) and screw in bolts (6).	Replace seals. Screw, bleed line for crankcase ventilation system to crankcase/timing case cover/oil separator/cylinder head cover	*BA01.20-P-1005-01R
		Set of protective covers	Fig 3
34	Secure cable bracket (5) of cylinder head cover (1).
35	Screw in screw (4).	Screw/bolt, oil separator to cylinder head cover	*BA01.20-P-1007-01R
36	Position cable duct (3) and screw in bolts (2).	Do not kink, subject lines to tension. Lines will otherwise be damaged. Screw, engine cable duct/engine wiring harness to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding	*BA01.20-P-1010-01R
37	Install coolant feed line for exhaust gas turbocharger.		AR20.20-P-1000MFG
38	Install oil feed line of exhaust gas turbocharger.		AR09.40-P-6022MFG
39	Install ignition coils.		AR15.12-P-2003MFG
40	Install lift solenoids of exhaust camshaft.		AR05.20-P-6558MFG
41	Install rear cap on cylinder head.		AR01.30-P-5702MFG
42	Fill in coolant.	Only install lower engine compartment paneling after leak test.	AR20.00-P-1142MFG
43	Connect ground line to battery.		AR54.10-P-0003MFA
	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
44	Perform engine test run. While doing so, check engine for proper operation and leak tightness.
45	Install upper engine cover.		AP01.10-P-2405-01K
46	Install lower engine compartment lining.		AR61.20-P-1105MFR