Remove/install cylinder head

AR01.30-P-5800L

Remove/install cylinder head

14.2.12

17.4.02

Value modified from 14 Nm to 1.5 Nm 1st stage and 14 Nm 2nd stage

Value in BA05.20-P-1003-01E for engine 137 modified

*BA05.20-P-1003-01E

12.6.02

Value changed from 80 Nm to 120 Nm

Figure in BA05.10-P-1001-01H for engine 137 modified

*BA05.10-P-1001-01H

 

Remove/install

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fire, sparks, open flames or smoking. Wear acid-resistant gloves,
clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect battery ground line

AR54.10-P-0003I

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

2

Remove engine compartment paneling

AR61.20-P-1105M

Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

3

Drain coolant at radiator

AR20.00-P-1142HA

4

Remove thermostat housing (12)

See 

Remove coolant thermostat

AR20.10-P-2460L

5

Remove fan shroud with suction fan (1)

AR20.40-P-6800AC

6

Remove poly-V belt (3)

 Installation:

Arrest clamping device with journal or pin (diameter 5 mm).

AR13.22-P-1202L

7

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

8

Remove air filter (2)

AR09.10-P-1050L

9

Remove ECI mains unit

 Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

10

Release fuel pressure through service valve (1/1)

 Collect fuel.

11

Remove fuel feed line

 Bending away of the fuel feed line is not permitted. There is a risk of crack formation at the fuel rail, and also at the fuel feed line. Open tank lock before disconnecting.

 Collect fuel.



*BA07.52-P-1001-01A

12

Remove intake manifold (7)

To remove the leaks the intake manifold (7) must only be removed complete with inlet connection, inlet air pipes (5, 6) and the fuel distributor (4).

AR09.20-P-1310L



*BA09.20-P-1001-01G

13

Disconnect coolant hose for heating system heat exchanger at firewall connection

14

Remove cylinder head covers (8, 9)

AR01.20-P-5014L



*BA01.20-P-1001-01E

15

Remove oil pump (10) for cylinder shutoff (CSO)

AR01.30-P-5704L



*BA01.30-P-1003-01G

16

Remove front cover on right (11)

AR01.30-P-5700L



*BA01.30-P-1001-01G



*BA01.30-P-1002-01G

17

Unbolt exhaust system at exhaust manifold



*BA14.10-P-1002-01B

18

Position engine to 30° after ignition TDC of cylinder 1

Crank engine at crankshaft in direction of rotation of engine until 30° marking on belt pulley/vibration damper is aligned with marking on timing case cover.

 Engine must not be cranked back.

19

Remove camshaft adjusters (14, 15)

 Mark camshaft adjusters and timing chain to each other with colored dots.

AR05.20-P-7201L

 Double open-ended wrench

*104589010100

 Retaining clamp

*137589004000

Holding device

*137589014000



*BA05.20-P-1001-01E



*BA05.20-P-1002-01E

 Installation: 

Check engine valve timing

AR05.10-P-6858L

If necessary, after inspecting: 

Set basic position of camshafts

AR05.20-P-6020L

20

Remove chain tensioner (13)

AR05.10-P-7800L



*BA05.10-P-1001-01H

21

Remove cylinder shutoff valves (Y80/1, Y81/1)

 Installation: Center cylinder shutoff valves on camshaft bearing caps so as to ensure a proper seal to the cylinder head cover.

AR01.30-P-5705L



*BA05.20-P-1005-01E

22

Remove camshaft bearing caps (16)

 Oil line (17) bolted to camshaft bearing housing.

AR05.20-P-7103L



*BA05.20-P-1003-01E

23

Remove sliding rail bolt (26)

 Pins are of different lengths.

Threaded bolt

*116589013400

Impact extractor

*116589203300

24

Remove bolts (18) for left cylinder head to timing case cover



*BA01.40-P-1002-01C

25

Remove bolts (19) of right cylinder head to timing case cover



*BA01.40-P-1002-01C

26

Loosen and unscrew the cylinder head bolts (20, 21) in stages

 Slacken cylinder head bolts as specified in slackening diagram once engine has cooled down: 

Slackening diagram for cylinder head bolts

AR01.30-P-5800-09L

 Pay attention to different lengths of bolts.

27

Take off cylinder heads (24, 25)

 Installation: Replace cylinder head gaskets (22, 23). Pay attention to tightening procedure and tightening instructions of the cylinder head bolts. Oil thread and head contact surface of cylinder head bolts.

AR01.30-P-5800-07L

 Torque wrench

*001589722100

 Screwdriver bit

*000589031000

 Screwdriver bit

*000589041000



*BA01.30-P-1004-01G

28

Inspect cylinder head bolts (20, 21)



AR01.30-P-5800-03L

29

Clean sealing surfaces and inspect for cracks, shrink holes and flatness; clean bolt holes

 Sealing surfaces of crankcase and cylinder head are provided with an 0.8 mm thick silicone layer during series production. Silicone sealant is applied in the gasket area when carrying out repairs only if shrink holes are present.

*BR00.45-Z-1013-01A

 The sealant must be applied within 10 minutes.

 Observe dowel sleeves for locating the cylinder head.

Loctite 5970 sealant

*BR00.45-Z-1013-01A



*112589002500

30

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

31

Start engine

32

Check for leaks with engine running

33

Inspecting cooling system for leaks

 Warm up engine to operating temperature and then inspect cooling system or leaks.

AR20.00-P-1010HA

34

Read out fault memory



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
137

BA01.20-P-1001-01E

Cylinder head cover bolt

Stage 1

Nm

8

Stage 2

°

-

Number

Designation

Engine 137

BA01.30-P-1001-01G

Right front cover to cylinder head

M6

Nm

8

BA01.30-P-1002-01G

Bolt, guide pulley to front cover on right

M8

Nm

30

BA01.30-P-1003-01G

Secondary-oil pump for cylinder shutoff to left cylinder head

M6

Nm

8

BA01.30-P-1004-01G

Internal Torx bolt, cylinder head to crankcase

Stage 1

Nm

20

Stage 2

° 

90

Stage 3

° 

90

Number

Designation

Engine
137

BA01.40-P-1002-01C

Bolt, cylinder head to timing case cover

Nm

8

Number

Designation

Engine
137

BA05.10-P-1001-01H

Chain tensioner in cylinder head

Nm

120

Number

Designation

Engine 137

BA05.20-P-1001-01E

Bolt for left camshaft adjuster

M14 x 80

Stage 1

Nm

120

Stage 2

°

90

BA05.20-P-1002-01E

Bolt of right camshaft adjuster

M14x48

Stage 1

Nm

120

Stage 2

°

90

BA05.20-P-1003-01E

Bolt connecting camshaft bearing cap to cylinder head

Stage 1

Nm

1.5

Stage 2

Nm

14

BA05.20-P-1004-01E

Bolt connecting camshaft bearing bridge to cylinder head

M7x85

Nm

14

BA05.20-P-1005-01E

Bolt connecting camshaft bearing bridge to cylinder head

M7x110

Nm

14

Number

Designation

Engine
137

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

Number

Designation

Engine 137

BA09.20-P-1001-01G

Bolt, intake manifold to cylinder head

Stage 1

M6

Nm

8

M8

Nm

20

Stage 2

M6

Nm

8

Stage 3

M6

 °

90

Number

Designation

Engine
137

BA14.10-P-1002-01B

Flange connection, exhaust manifold/front exhaust pipes

Nm

20

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite 5970 sealant

A 003 989 98 20