Remove/install cover on cylinder head - AR01.30-P-5701CD
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MODEL 166 with ENGINE 651
MODEL 172 with ENGINE 651
MODEL 204 with ENGINE 651
MODEL 207 with ENGINE 651
MODEL 212 with ENGINE 651
MODEL 218 with ENGINE 651
MODEL 221 with ENGINE 651
MODIFICATION NOTES
| 2.10.12 | exhaust gas recirculation pipe to timing case cover Screw | BA14.20-P-1003-01K |
Shown on model 204.002
| Remove/install | |||
| 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 explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure | Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized. | AS07.16-Z-0001-01A | |
| Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. | Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. |
AS20.00-Z-0001-01A | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| 1 | Remove cylinder head cover trim | ||
| 2 | Drain coolant at radiator | MODEL 166 | AR20.00-P-1142GQ |
| MODEL 172, 204, 207 | AR20.00-P-1142CW | ||
| MODEL 212 (except 212.098/298), 218, 221 Do not pressure-test cooling system until engine has reached operating temperature. Leaks can occur on the cylinder head gasket otherwise. |
AR20.00-P-1142OMA | ||
| 3 | Remove air filter housing | AR09.10-P-1150CD | |
| 4 | Disconnect electrical connector (1) at pressure differential sensor (DPF) (B288) | ||
| 5 | Remove screw/bolt (2), loosen clamp and remove DPF differential pressure sensor (B28/8) from air filter housing bracket | ||
| *BA07.04-P-1004-01L | |||
| 6 | Disconnect electrical connectors (3, 4), unhook engine wiring harness from bracket (5) and lay to one side | ||
| 7 | Remove screw/bolts (6) and remove air filter housing bracket at the rear | *BA09.10-P-1001-01K | |
| 8 | Remove sealing (11) on partition wall (7) | ||
| 9 | Unlock and detach vacuum line (8) on partition wall (7) | Model 172, 204, 207, 212, 218, 221 | |
| 10 | Disconnect coolant hose (9) on partition wall (7) | Henn coupling | |
| AR09.41-P-1311-01AL | |||
| 11.1 | Remove battery cover (10) | Model 172, 204, 207, 212, 218, 221 | |
| 11.2 | Remove covers for air intake box on the right and battery device on the left | MODEL 166 | |
| 12 | Unfasten electrical wiring harness (12) on partition wall (7) | Model 204, 207, 212, 218, 221 |
|
| 13 | Unscrew nuts (16), loosen retaining clamps all around and detach heat shield (15) from the threaded pins on the partition wall (7) | ||
| 14.1 | Remove expansion rivets (13), detach partition wall (7) somewhat in the area of the wiper linkage, remove screw/bolt on bracket (14) and remove partition wall (7) | Model 172, 204, 207, 212, 218, 221 | |
| 14.2 | Remove partition wall (7) | MODEL 166 | |
| 15 | Remove cylinder head cover | AR01.20-P-5014CD | |
| 16 | Remove heat shield over flexible exhaust gas recirculation pipe (17) | ||
| 17 | Remove screw/bolts (18, 19) and take off flexible exhaust gas recirculation pipe (17) | ||
| *BA14.20-P-1002-01K | |||
| *BA14.20-P-1003-01K | |||
| 18 | Remove screws/bolts (21) | ||
| *BA14.20-P-1011-01K | |||
| 19 | Remove screw/bolts (22) | *BA05.10-P-1002-01Q | |
| 20 | Pry off cover (20) | ||
| Clean | |||
| 21 | Clean sealing surfaces on cylinder head, cover (20), exhaust manifold and EGR line | Do not use sharp-edged or pointed objects to clean sealing surfaces. The sealing surfaces can get damaged otherwise. |
|
| 22 | Install in the reverse order | ||
| 23 | Inspect cooling system for leaks | MODEL 166 | AR20.00-P-1010GQ |
| MODEL 172, 204, 207 | AR20.00-P-1010CW | ||
| MODEL 212, 218 | AR20.00-P-1010OMA | ||
| MODEL 221 | AR20.00-P-1010SX | ||
| Check | |||
| 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 | |
| 24 | Check leaktightness of fuel system and the exhaust system in the area of the cylinder head and the cover (20) for a running engine |
SENSORS, TRANSMITTERS
| Number | Designation | ENGINE 651 | |
|---|---|---|---|
| BA07.04-P-1004-01L | Differential pressure sensor to bracket | Nm | 9 |
EXHAUST GAS RECIRCULATION
| Number | Designation | ENGINE 651 | |
|---|---|---|---|
| BA14.20-P-1011-01K | Bolt, exhaust gas recirculation line to chain case cover | Nm | 9 |
EXHAUST GAS RECIRCULATION
| Number | Designation | ENGINE 651 | ||
|---|---|---|---|---|
| BA14.20-P-1002-01K | Bolt, exhaust gas recirculation pipe to exhaust manifold | Stage 1 | Nm | 12 |
| Stage 2 | ∠° | 90 | ||
AIR FILTER
| Number | Designation | ENGINE 651 | |
|---|---|---|---|
| BA09.10-P-1001-01K | Screw/bolt, air filter bracket to cylinder head | Nm | 9 |
EXHAUST GAS RECIRCULATION
| Number | Designation | ENGINE 651 | |
|---|---|---|---|
| BA14.20-P-1003-01K | Bolt, exhaust gas recirculation pipe to chain case cover | Nm | 10 |
TIMING CHAIN, CHAIN TENSIONER
| Number | Designation | ENGINE 651 | |
|---|---|---|---|
| BA05.10-P-1002-01Q | Chain case cover to cylinder head | Nm | 9 |