Remove/install cylinder head

AR01.30-P-5800EVO

Remove/install cylinder head

18.02.2020

Engine

271.8 in model 172, 204, 207, 212

Modification notes

23.08.2019

Note added.

Operation step 31

1

Valve unit

2

Air ducting

3

Vacuum hose

4

Heat shield

5

Boost pressure control hose

9

Charge air line

1

Valve unit

8

Coolant pipe

11

Electrical line

5

Boost pressure control hose

10

Electrical line

12

Bracket

6

Crankcase ventilation system pipe

 

Remove/install

1

Remove ground line from battery.

Model 172

AR54.10-P-0003W

Topical note

Notes on battery

AH54.10-P-0001-01A

model 204

AR54.10-P-0003CW

ENGINE 207, 212

AR54.10-P-0003EW

2

Remove the catalytic converter.

AR49.10-P-5500EVO

3

Drain off coolant.

AR20.00-P-1142CW

Topical note

Notes on coolant

AH20.00-N-2080-01A

4

Remove vacuum hose (3) from radiator shutter's adjuster.

Only if fitted.

5

Remove air ducting (2) from exhaust gas turbocharger.

6

Detach boost pressure control hose (5) from pressure transducer.

7

Remove charge air line (9) from exhaust gas turbocharger.

AR09.41-P-1311-01AL

8

Remove heat shield (4) and support from the exhaust gas turbocharger.

AR09.40-P-6025EVO

9

Remove power steering expansion reservoir.

AR46.25-P-1000EVO

 Place the expansion reservoir to one side with lines connected.

10

Remove valve unit (1).

MODEL 204, 207, 212

AR14.30-P-7100EVO

 Model 172
If installed.

11

Remove bracket (12) from cylinder head.

12

Remove oil return feed line of the exhaust gas turbocharger.

AR09.40-P-6020-13EVO

 Banjo bolt, oil feed line to turbocharger

*BA09.40-P-1007-01Q

 Bolt, oil feed line to cylinder head

*BA09.40-P-1008-01Q

 Bolt, coolant return line/oil feed line holder to turbocharger

*BA09.40-P-1009-01Q

 Bolt, oil return flow line to turbocharger

*BA09.40-P-1010-01Q

13

Remove coolant feed pipe for turbocharger.

AR09.40-P-6020-14EVO

 Bolt, coolant return line flange to turbocharger

*BA09.40-P-1005-01Q

 Bolt, coolant feed pipe to crankcase

*BA09.40-P-1006-01Q

 Bolt, coolant return line/oil feed line holder to turbocharger

*BA09.40-P-1009-01Q

14

Remove crankcase ventilation system pipe (6) and coolant pipe (8).

15

Remove cylinder head cover.

AR01.20-P-5014CW

16

Remove oil dipstick tube.

AR18.40-P-3510EVO

17

Remove the vacuum pump.

AR43.05-P-1320CW

18

Remove the intake manifold.

AR09.20-P-1310EVO

19

Disconnect plug coupling for electrical line (10) on rail pressure sensor.

20

Disconnect plug coupling for electrical line (11) for fuel injectors from rail.

21

Remove the high-pressure pump.

AR07.02-P-1020EVO

22

Remove coolant connection from cylinder head at the rear.

23

Remove the front cover at the cylinder head.

AR01.30-P-5700CW

24

Remove the chain tensioner.

AR05.10-P-7800EVO

25

Pull the guide rail pins out of cylinder head.

AR01.30-P-5800-04GS

 Use a screwdriver to remove the stop plug.

 Impact extractor

*116589203300

 Threaded bolt

*116589023400

 Puller

*605589003300

26

Remove camshaft positioner of exhaust camshaft.

AR05.20-P-7201CW

27

Remove tensioning rail.

AR05.10-P-8127CW

28

Remove camshaft housing.

AR05.20-P-6995CW

29

Remove the roller cam follower with compensating elements.

 When removing more than one compensation elements, ensure that cam followers and compensation elements which were not replaced are re-installed at their previous location. Mark roller cam follower relative to the compensation element if necessary.

30

Loosen cylinder head bolts in stages and remove them.

AR01.30-P-5800-07QA


Slacken the cylinder head bolts in the reverse order of the tightening procedure when the engine has cooled off.
This avoids stresses in the cylinder head.

 Screw/bolt, cylinder head

*BA01.30-P-1002-01J

 Screw/bolt, cylinder head to timing case cover

*BA01.40-P-1002-01G

31

Remove cylinder head.

General information on checking valves, valve seats and valve guides

AH05.30-P-1000-02SZ

 Installation: Replace cylinder head gasket. While putting the cylinder head in place, observe the guide pin for fixing the cylinder head in place.



Clean

32

Clean the sealing surfaces of cylinder head and crankcase.

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

33

Check sealing surfaces on cylinder head and crankcase for cracks and unevennesses.


Cylinder head and crankcase must not be reworked (surface grinding).
The manufacturing tolerances must be maintained.

34

Blow out tapped holes of the cylinder head bolts with compressed air and clean from oil and water.

35

Check cylinder head bolts and replace if necessary.

AR01.30-P-5800-03HA

Cylinder head bolt

*BE01.30-P-1001-04B

36

Install in the reverse order.

Check

37

Check engine oil level and correct if necessary.



AP18.00-P-0101AB

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

38

Perform engine test run and check engine in terms of leak tightness while engine is running.

Cylinder head/cylinder head bolts

Number

Designation

Engine 271

BE01.30-P-1001-04B

Cylinder head bolt

Thread diameter

M

101,5

Length (L) when new

mm

165

Length (L)

mm

167,5

For picture, see

-

 Cylinder head

Number

Designation

Engine 271

BA01.30-P-1002-01J

Screw/bolt, cylinder head

M10

Stage 1

Nm

45

Stage 2

°

90

Stage 3

°

90

For picture, see

–

 Cylinder crankcase, timing case cover, end cover

Number

Designation

Engine 271

BA01.40-P-1002-01G

Screw/bolt, cylinder head to timing case cover

Stage 1

Nm

20

Stage 2

°

–

 Turbocharger

Number

Designation

Engine 271.8

BA09.40-P-1005-01Q

Bolt, coolant return line flange to turbocharger

Nm

9

 Turbocharger

Number

Designation

Engine 271.8

BA09.40-P-1006-01Q

Bolt, coolant feed pipe to crankcase

Nm

9

 Turbocharger

Number

Designation

Engine 271.8

BA09.40-P-1007-01Q

Banjo bolt, oil feed line to turbocharger

Stage 1

Nm

6

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 271.8

BA09.40-P-1008-01Q

Bolt, oil feed line to cylinder head

Nm

9

 Turbocharger

Number

Designation

Engine 271.8

BA09.40-P-1009-01Q

Bolt, coolant return line/oil feed line holder to turbocharger

Nm

9

 Turbocharger

Number

Designation

Engine 271.8

BA09.40-P-1010-01Q

Bolt, oil return flow line to turbocharger

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09