Remove/install cylinder head

AR01.30-P-5800TK

Remove/install cylinder head

06.03.2020

Engine

271.941 in model 211.042/242

Engine

271.956 in model 211.041/241

Modification notes

05.08.2019

AH05.30-P-1000-02SZ, added.

Operation step 18

1

Heat shield

4

Bracket

5

Screw

6

Bolts

7

Exhaust manifold with CAT

10

Coolant line

11

Coolant line

12

Fuel feed line

2

Slide rail pins

3

Cylinder head

17

Cylinder head bolts

18

Cylinder head seal

20

Bolts

21

Inlet and pressure connection

M16/6

Throttle valve actuator

 

Remove/install

1

Drain coolant from the cooler and bleed crankcase.

AR20.00-P-1142T

Topical note

Notes on coolant

AH20.00-N-2080-01A

2

Remove screw (5), loosen screws (6), and remove exhaust manifold with catalytic converter (7) from the bracket (4).

 Installation: Replace bolt (5)

 Bolt connecting bracket for front exhaust system to transmission

*BA49.10-P-1005-01K

 Bolt connecting exhaust manifold with catalytic converter to bracket

*BA49.10-P-1010-01K

3

Remove air filter housing.

AR09.10-P-1150Q

4

Remove camshaft housing.

AR05.20-P-6995QK

 Use wedge to slacken the timing chain.

 Key

*271589003100

5

Remove hydraulic valve play compensation elements.

AR05.00-P-2011QK

6

Remove heat shield (1).

 Shield to camshaft bearing housing

*BA05.20-P-1004-03A

7

Remove exhaust manifold with catalytic converter (7) from the cylinder head (3).

AR14.10-P-4095TK

 Only disassemble exhaust manifold with catalytic converter (7) and press to one side; do not remove.

8

Remove oil dipstick tube from the cylinder head (3).

9

Remove coolant lines (10, 11) from the cylinder head (3).

 Screw/bolt, coolant thermostat housing to cylinder head

*BA20.10-P-1003-01I

 Screw/bolt, coolant line to cylinder head

*BA20.10-P-1004-01I

10

Remove engine wiring harness.

AR01.00-P-2410-02CW

 Screw/bolt, ground line to front cover

*BA01.30-P-1001-01J

11

Remove screws (20) and remove suction and pressure connection (21) from the throttle valve actuator (M16/6).

 Screw/bolt, charge air duct downstream of charge air cooler to pressure damper

*BA09.41-P-1004-02A

12

Pull out slide rail bolt (2) at the cylinder head (3).

AR01.30-P-5800-04GS

 Remove stop plug with screwdriver.

 Impact extractor

*116589203300

 Threaded bolt

*116589013400

 Puller

*605589003300

13

Remove wedge.

 Installation: Pull timing chain upward and keep under tension while doing so.

 Key

*271589003100

14

Remove tensioning rail.

AR05.10-P-8127TK

15

Remove fuel pressure.

AR07.03-P-1460-01TK

 Pressure hose

*119589046300

16

Remove fuel feed line (12) from the fuel distributor.

 Fuel feed line to fuel distributor

*BA07.52-P-1002-01B

17

Loosen cylinder head bolts (17) in stages and remove.

AR01.30-P-5800-07QA


Loosen cylinder head bolts (17) in reverse order of the tightening procedure once the engine has cooled down.
Otherwise, distortion of the cylinder head (3) will occur.

 Screw/bolt, cylinder head

*BA01.30-P-1002-01J

 Screw/bolt, cylinder head to timing case cover

*BA01.40-P-1002-01G

18

Remove cylinder head (3).

General information on checking valves, valve seats and valve guides

AH05.30-P-1000-02SZ

 Installation: Install new cylinder head gasket (18). When positioning the cylinder head (3), pay attention to the guide pins for fixing the cylinder head (3) in place.



Clean

19

Clean sealing surfaces of cylinder head (3) and crankcase.

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

Assembly cleaner

*BR00.45-Z-1028-04A

20

Check sealing surfaces of the cylinder head (3) and crankcase for cracks and unevenness.


Do not rework cylinder head (3) and crankcase (surface grinding).
Otherwise, the permissible machining tolerances will be exceeded.

21

Blow out threaded holes of the cylinder head bolts (17) with compressed air and clean off any oil and water.

22

Check cylinder head bolts (17); replace if necessary.

AR01.30-P-5800-03HA

Cylinder head bolt

*BE01.30-P-1001-04B

23

Install in the reverse order.

Check

24

Check engine oil level.

 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

25

Check for oil leaks with the engine 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-1001-01J

Screw/bolt, ground line to front cover

M6

Nm

8

 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

°

–

 Camshaft bearing housing

Number

Designation

Engine 271

BA05.20-P-1004-03A

Shield to camshaft bearing housing

M6

Nm

8

 Fuel distributor

Number

Designation

Engine 271.9

BA07.52-P-1002-01B

Fuel feed line to fuel distributor

Nm

24

 Charge air duct

Number

Designation

Engine 271

BA09.41-P-1004-02A

Screw/bolt, charge air duct downstream of charge air cooler to pressure damper

Nm

8

 Coolant pump, coolant thermostat

Number

Designation

Engine 271

BA20.10-P-1003-01I

Screw/bolt, coolant thermostat housing to cylinder head

Nm

9

 Coolant pump, coolant thermostat

Number

Designation

Engine 271

BA20.10-P-1004-01I

Screw/bolt, coolant line to cylinder head

Nm

9

 Exhaust system

Number

Designation

Engine 271 in model 211

BA49.10-P-1005-01K

Bolt connecting bracket for front exhaust system to transmission

Nm

20

 Exhaust system

Number

Designation

Engine 271 in model 211

BA49.10-P-1010-01K

Bolt connecting exhaust manifold with catalytic converter to bracket

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01