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Remove/install cylinder head cover - AR01.20-P-5014CD

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ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221 

Fig 1: Cylinder Head Cover Remove/Install Components
G09973791Courtesy of MERCEDES-BENZ USA

Shown on model 204 

Fig 2: Cylinder Head Cover Remove/Install Components - Shown On Model 204 (1 Of 2)
G09973792Courtesy of MERCEDES-BENZ USA
Fig 3: Cylinder Head Cover Remove/Install Components - Shown On Model 204 (2 Of 2)
G09973793Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER 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
IMPORTANT Notes about Common-Rail components   AH07.16-P-0002-01TX
1 Remove trim panel of cylinder head cover (2)    
2 Remove section for partition wall on the left and center Model 166  
3 Remove air filter housing   AR09.10-P-1150CD
4 Detach bleed hose for crankcase ventilation system (1)    
5 Remove injectors   AR07.16-P-1000CD
6 Disconnect electrical connectors (7)    
7 Disconnect electrical connector (8) Except model 166  
8 Lift fastening clips (9), wiring shaft (10) with engine wiring harness and place to one side somewhat INSTALLATION IMPORTANT Cable bracket which are separated when removing, must be fitted again at the same position when installing.  
9 Remove banjo bolt (4) and remove return line on rail IMPORTANT Close off connections after unscrewing.
INSTALLATION IMPORTANT Replace sealing rings.
 
    TORQUE SPECIFICATION *BA07.16-P-1004-01H 
10 Remove screw/bolts (3) and cylinder head cover (2) INSTALLATION IMPORTANT Replace seal (5) for cylinder head cover (2).
Push seal (5) over the collar of the respective screw/bolt (3) and press into the slot (6) around the whole circumference.
 
    TORQUE SPECIFICATION *BA01.20-P-1001-01Q 
11 Install in the reverse order    
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.
AS00.00-Z-0005-01A
12 Check leaktightness of fuel system and cylinder head cover (2) when engine is running    
CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number Designation Engine 651
BA01.20-P-1001-01Q Screw/bolt, cylinder head cover to cylinder head Nm 9
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation Engine 651
BA07.16-P-1004-01H Banjo Screw/bolt, return line to rail Nm 25