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Remove/install left cylinder head cover - AR01.20-P-5013SXI

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ENGINES 642 in MODEL 207, 212, 218, 221 

Shown on engine 642.930 in model 221 

Fig 1: Left Cylinder Head Cover Remove/Install Components - Shown On Engine 642.930 In Model 221
G09973786Courtesy of MERCEDES-BENZ USA

Turbocharger without coolant cooling 

Fig 2: Left Cylinder Head Cover Remove/Install Components (Turbocharger Without Coolant Cooling)
G09973787Courtesy of MERCEDES-BENZ USA

Turbocharger with coolant cooling 

Fig 3: Left Cylinder Head Cover Remove/Install Components (Turbocharger With Coolant Cooling)
G09973788Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

9.4.10 Value changed: bolt, cylinder head cover on cylinder head   *BA01.20-P-1001-01P 
REMOVINGINSTALLING Remove/install     
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
1 Remove engine air intake duct downstream of air filter Model 207, 212, 218 AR09.10-P-8130OGE
    Model 221 AR09.10-P-8130SXI
2.1 Remove engine charge air duct on turbocharger (14b) Engine 642 with turbocharger (14b) with coolant cooling. AR09.41-P-8622SXI
2.2 Remove engine charge air channel upstream of charge air cooler Model 221 with turbocharger (14a) without coolant cooling AR09.41-P-8623SXI
3 Remove exhaust gas recirculation positioner Model 207, 212, 218 AR14.20-P-1020GZB
    Model 221 AR14.20-P-1020SXI
4 Remove fuel injectors   AR07.16-P-1000SXI
5 Remove rail   AR07.03-P-1010SXI
6 Detach container for the power steering pump on cylinder head cover IMPORTANT Place power steering pump container to one side.  
    Model 207 AR46.25-P-1000CO
    Model 212 AR46.25-P-1000EWO
    Model 221 without code (487) Active Body Control (ABC) without electrohydraulic P/S (EHPS) AR46.25-P-1000SXI
7 Unscrew fuel line (1) on cylinder head cover and remove with the flexible feed and return hose    
8 Loosen guide tube (3) IMPORTANT Loosen guide tube (3) above and below. A small amount of oil may flow out; this should be caught.  
    TORQUE SPECIFICATION *BA18.40-P-1001-01M 
9 Loosen cylinder head cover bolt in stages and remove NOTES Slacken cylinder head bolts in the reverse sequence of the tightening procedure when the engine has cooled down so that the cylinder head cover is not warped.  
    Bolt tightening procedure for cylinder head cover AR01.20-P-5014-03SXI 
    INSTALLATION NOTES Pay attention to the tightening procedure and the tightening instructions for the cylinder head bolts so that the cylinder head cover is not warped and the camshafts are not damaged.  
    TORQUE SPECIFICATION *BA01.20-P-1001-01P 
10 Remove cylinder head cover IMPORTANT Detach cylinder head cover if necessary using the SPECIAL TOOL impact extractor and SPECIAL TOOL threaded bolt and then remove.  
    SPECIAL TOOL Threaded stud Fig 5
    SPECIAL TOOL Impact extractor Fig 4
    Loctite 5970 sealant *BR00.45-Z-1013-01A 
IMPORTANT Notes on sealant path for cylinder head cover   AH01.30-P-1000-08SXI
CLEANING Clean     
11 Clean sealing surfaces on the cylinder head cover and cylinder head NOTES Do not use any sharp-edged tools and no grinding paper otherwise the sealing surfaces will be damaged. AR01.00-P-0050-01A
    Loctite 7200 *BR00.45-Z-1038-04A 
    Cleaning spray, Loctite 7063 (150ml) *BR00.45-Z-1046-04A 
12 Install in the reverse order    
INSPECT Checking     
13 Check engine oil level NOTES In order to avoid measurement errors, vehicle must be parked on an even surface.
IMPORTANT Inspect engine oil level about 5 min. after switching off warm engine		 AR18.00-P-3035-01SXI
    FLUID SPECIFICATION Without code (474) Particulate filter *BF18.00-P-1001-01A 
    FLUID SPECIFICATION With code (474) Particulate filter *BF18.00-P-1001-01S 
14 Check for oil leaks with engine running    
15 Check fuel system for leaks with engine running    
CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number Designation Engine 642
BA01.20-P-1001-01P Bolt, cylinder head cover to cylinder head Stage 1, apply Nm 4
Stage 2, initial torque Nm 6
Stage 3, final torque Nm 9
OIL LEVEL, OIL PRESSURE SENSOR

Number Designation Engine 642
BA18.40-P-1001-01M Bolt for oil dipstick guide tube Nm 11
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642.826/830/832/834/836/838/850/852/853/854/856/858/862/868 with particulate filter
BF18.00-P-1001-01S Engine oil Filling capacity (oil and filter change) Liters 8.0
Specifications for Operating Fluids Specifications Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642.930 with particulate filter up to engine No. 64293040458147 Engine 642.930 with particulate filter starting from engine No. 64293040458148 Engine 642.932/961 with particulate filter
BF18.00-P-1001-01S Engine oil Filling capacity (oil and filter change) Liters 9.5 8.0 8.0
Specifications for Operating Fluids Specifications Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642.930 without particulate filter up to engine no. 64293040458147 Engine 642.930 without particulate filter as of engine no. 64293040458148 Engine 642.932/961 without particulate filter
BF18.00-P-1001-01A Engine oil Filling capacity (oil and filter change) Liters 9.5 8.0 8.0
Specifications for Operating Fluids Specifications BB00.40-P-0228-03A BB00.40-P-0228-03A BB00.40-P-0228-03A
Specifications BB00.40-P-0228-05A BB00.40-P-0228-05A BB00.40-P-0228-05A
Specifications Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications BB00.40-P-0229-03A BB00.40-P-0229-03A BB00.40-P-0229-03A
Specifications Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications BB00.40-P-0229-05A BB00.40-P-0229-05A BB00.40-P-0229-05A
Specifications Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
Fig 4: Identifying Impact Extractor (116 589 20 33 00)
G09973789Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Threaded Stud (102 589 00 34 00)
G09973790Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A Cleaning spray, Loctite 7063 (150ml) A 001 986 71 71 10
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