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6-Cylinder Engine Valve Cover Gasket Replacement
 
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Pelican Technical Article:

6-Cylinder Engine Valve Cover Gasket Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$200

Talent:

****

Tools:

E10 inverted Torx, T30 Torx, 8mm socket, 17mm wrench, flathead screwdriver

Applicable Models:

Mercedes-Benz W211 (2003-09)

Parts Required:

Valve cover gasket, RTV (silicone sealant)

Hot Tip:

Work with a cool engine

Performance Gain:

Repair oil leaks

Complementary Modification:

Change engine oil and filter, as well as change spark plugs

In order for an engine to function it needs engine oil to lubricate reciprocating parts. This means that the engine covers need to have seals to prevent engine oil from leaking out. One of the most common jobs to perform is replacing the valve cover gasket. Mercedes-Benz uses a rubber seal to form the valve cover gasket. This seal can shrink as a result of the heat cycles that the engine generates as the car is used. This will allow engine oil that is thinner from the engine to seep past the seal and form a layer of oil coating the engine. In this tech article we will go over all the steps to replace the valve cover gasket.

The valve cover gasket is one of the most common places to have an oil leak on your W211. If you have an oil leak down the exhaust side or front of your engine, start at the top and replace the valve cover gasket. When the valve cover gasket leaks, it can create quite a mess and seem much worse than it is.

Engine oil can also leak from the breather covers and looks a lot like a valve cover leak. If you suspect the breather covers are leaking, remove the ignition coils and inspect the area around the breather covers for leaks. See our tech article on breather hoses and covers replacing for more information.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

In this tech article, I will show you how to remove the necessary components from each side of the engine to access the valve covers. Then I will show how to remove the right side valve cover. The right side is similar.

Disconnect the battery. See our tech article on battery replacing.

Working at the engine cover (red arrow), pull off the two front air duct hoses (green arrows).
Figure 1

Working at the engine cover (red arrow), pull off the two front air duct hoses (green arrows).

To detach the ducts, pull them straight off the engine cover / air filter housing.
Figure 2

To detach the ducts, pull them straight off the engine cover / air filter housing. Then pull the front of the duct out of the radiator support and remove from the engine. Repeat this step for each duct.

Lift up and remove the front engine cover.
Figure 3

Lift up and remove the front engine cover.

Then, pull the engine cover / air filter housing straight up to remove it.
Figure 4

Then, pull the engine cover / air filter housing straight up to remove it. The cover is held on by four metal clips that grab onto rubber mounts, with the front two shown (red arrows). The rear of the cover has two as well. Once detached, remove the engine cover / air filter housing from the engine.

Working at the right side valve cover, pull the breather hose straight off the breather cover to remove it.
Figure 5

Working at the right side valve cover, pull the breather hose straight off the breather cover to remove it.

Working at the left side valve cover, pull the breather hose (green arrow) out of the mounts running under the wiring harness holder.
Figure 6

Working at the left side valve cover, pull the breather hose (green arrow) out of the mounts running under the wiring harness holder.

Working at the left side valve cover, pull the breather hose (red arrow) straight off the breather cover to remove it.
Figure 7

Working at the left side valve cover, pull the breather hose (red arrow) straight off the breather cover to remove it.

Working at the left side valve cover, pull the final breather hose (red arrow) straight off the breather cover to remove it.
Figure 8

Working at the left side valve cover, pull the final breather hose (red arrow) straight off the breather cover to remove it. Once all the breather hoses are detached, remove the ignition coils. See our tech article on spark plug, ignition coil and wire replacing.

Back at the right side of the engine, remove the fuel pressure test port cap (red arrow).
Figure 9

Back at the right side of the engine, remove the fuel pressure test port cap (red arrow). Then cover the port with a rag and press the Schrader valve down to relieve the fuel pressure. Reinstall the cap once pressure is relieved.

Working at the left side of the engine, use a 17mm line wrench and remove the fuel line at the fuel rail.
Figure 10

Working at the left side of the engine, use a 17mm line wrench and remove the fuel line at the fuel rail. Once removed, cover the line and fitting on the fuel rail with a rag to collect excess fuel.

Remove the nine E10 valve cover fasteners (red arrows).
Figure 11

Remove the nine E10 valve cover fasteners (red arrows).

I like to use a six-inch extension with a universal swivel to remove the fasteners.
Figure 12

I like to use a six-inch extension with a universal swivel to remove the fasteners.

Once all the fasteners are removed, move the engine oil tube away from the corner of the valve cover.
Figure 13

Once all the fasteners are removed, move the engine oil tube away from the corner of the valve cover.

Lift the valve cover off the cylinder head.
Figure 14

Lift the valve cover off the cylinder head. It should not be stuck to the cylinder head. If it is stuck, check that you didn't miss a fastener. At times the valve cover is stuck, I will gently lever it off using a pry bar (red arrow).

Remove the valve cover with the gasket from the cylinder head.
Figure 15

Remove the valve cover with the gasket from the cylinder head.

Once the valve cover has been removed, pull the valve cover gasket out of the valve cover.
Figure 16

Once the valve cover has been removed, pull the valve cover gasket out of the valve cover. Then thoroughly clean the valve cover sealing groove. Use a plastic gasket scraper so as not to damage the valve cover.

Install a new valve cover gasket into the groove in the valve cover.
Figure 17

Install a new valve cover gasket into the groove in the valve cover.

Then apply a small amount of RTV to the seams at the camshaft cutouts at each side of the cylinder head (front shown, red arrows, rear is similar).
Figure 18

Then apply a small amount of RTV to the seams at the camshaft cutouts at each side of the cylinder head (front shown, red arrows, rear is similar). Place the valve cover on the cylinder head and install all the fasteners finger tight. Then tighten the fasteners in a cross-cross pattern. Reinstall the ignition coils and install and route the wiring harness as previously installed. Start and idle the engine. Inspect the valve cover and surrounding areas for oil leaks. Once complete, reinstall the engine covers.

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Page last updated: Fri 12/2/2016 02:42:01 AM