Remove/install cylinder head

AR01.30-L-5800VA

Remove/install cylinder head

6.8.01

 

Remove/install

1

Disconnect ground cable of battery

AR54.10-P-0003A

2

Remove bottom part of noise encapsulation

 Only front engine compartment paneling.

AR94.30-L-5300VA

Danger!

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 bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A

3

Drain coolant at crankcase

AR20.00-L-1142VA



Notes on coolant

All engines

AH20.00-N-2080-01A

4

Remove coolant thermostat (6)

AR20.10-L-2460VA

5

Remove camshafts (7, 8)

AR05.20-L-6992VA

6

Remove drag lever (4)

 Reinstall drag lever (4) in same position.

7

Detach coolant hose (5) from cylinder head (1)

 Check collar clamps, replace if necessary.

8

Detach engine mount (10) from engine support (11)


 Support engine from below.

*BA22.10-P-1005-01I

9

Unscrew torx bolts (14) in chain case



*BA01.30-P-1002-01F

10

Slacken cylinder head bolts (13) in stages, unscrew

 Slacken cylinder head bolts in reverse order of tightening diagram once engine has cooled down 

Tightening diagram of cylinder head bolts

AR01.30-P-5800-01GF

 Installation: Lubricate thread and bolt head contact surface of cylinder head bolts, insert, and tighten in stages.



*BA01.30-P-1001-01F

11

Inspect cylinder head bolts (13)

AR01.30-P-5800-03GF



*BE01.30-P-1001-04D

12

Lift cylinder head (1) and remove

 Installation: replace cylinder head gasket (15).

 When installing cylinder head (1), guide the guide rail pins (12) in cylinder head into slide rail (18) (arrows).

 Pay attention to fitted sleeves (16) for locating cylinder head (1).

If cylinder head is replaced: 

Convert exhaust manifold (19).

 Replace gasket.

 Stud bolt

*BA14.10-P-1002-01D

Collared nut

*BA14.10-P-1001-01D

13

Clean separating surfaces, check for cracks and flatness, clean tapped holes

 Free of oil and water

14

Install in the reverse order

 Danger!

Risk of accident from vehicle starting off by itself when engine running. Risk of injury from bruises and burns if you insert your hands into the engine when it is started or when it is running.

Secure the vehicle to prevent it from moving off by itself.

Always wear appropriate work clothing when working on the vehicle

AS00.00-Z-0005-01A

15

Run engine and inspect for leaks

16

Check cooling system for leaks

 Do not pressure-test cooling system until engine has reached operating temperature.

 The cylinder head gasket is only watertight when the engine operating temperature is reached and the gasket has swollen.

AR20.00-P-1010GF

17

Read out fault memory



Connect STAR DIAGNOSIS, interrogate fault memory

AD00.00-P-2000-04A

Diagnosis system STAR DIAGNOSIS

*WH58.30-Z-1048-13A

Number

Designation

Engine 668.914

BE01.30-P-1001-04D

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

186

max. length (L)

mm

188

Number

Designation

Engine 668.914

BA01.30-P-1001-01F

Bolt of cylinder head to crankcase

1st stage

Nm

60

2nd stage

°

180

3rd stage

°

-

BA01.30-P-1002-01F

Bolt of cylinder head to timing case cover

Nm

20

Number

Designation

Engine 668.914

BA14.10-P-1001-01D

Collared nut, exhaust manifold to cylinder head

Nm

30

BA14.10-P-1002-01D

Stud bolt in cylinder head

Nm

9

Number

Designation

Engine 668.914

BA22.10-P-1005-01I

Bolt, engine support to engine mount

Nm

55

Number

Designation

WH58.30-Z-1048-13A

STAR DIAGNOSIS diagnosis system, Compact Passenger Car

6511 1801 00