Remove/install cylinder head

AR01.30-P-5800TS

Remove/install cylinder head

18.02.2020

Engine

272, 273 in model 211, 219

Left cylinder head

Modification notes

11.04.2014

Cylinder head bolt

Engine 272

BE01.30-P-1001-04B

11.04.2014

Cylinder head bolt

Engine 273

BE01.30-P-1001-04B

1

Cylinder crankcase

2

Catalytic converter

7

Cylinder head

15

Cylinder head seal

3

Poly-V-belt

8

Oil separator

12a

Intermediate flange

4

Power steering expansion reservoir

9

Cylinder head cover

13

Coolant hose

5

Oil filter housing

10

Intake manifold

14

Slide rail pins

6

Front cover

11

Camshaft adjuster

B11/4

Coolant temperature sensor

7

Cylinder head

12

Air shutoff valve

N3/10

ME-SFI [ME] control unit

 

Remove/install

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

1

Turn key in ignition lock to position "0"

2

Detach ground line from battery

Model 211.0 with engine 272, 273

AR54.10-P-0003T

Topical note

Notes on battery

AH54.10-P-0001-01A

Model 211.2 with engine 272, 273

AR54.10-P-0003TA

Model 219.3 with engine 272, 273

AR54.10-P-0003TX

3

Remove lower engine compartment paneling

Model 211 with engine 272, 273

AR61.20-P-1105T

Model 219 with engine 272, 273

AR61.20-P-1105TX

 Installation: Only install lower engine compartment paneling after the engine test run.

4

Drain coolant at radiator and at cylinder crankcase (1)

AR20.00-P-1142TS

Topical note

Notes on coolant

AH20.00-N-2080-01A

5

Detach left catalytic converter (2) from exhaust manifold

 Model 211 with engine 272, 273Bolt, catalytic converter to exhaust manifold

*BA49.10-P-1001-01T

 Model 219 with engine 272, 273Screw/bolt, catalytic converter to exhaust manifold

*BA49.10-P-1001-01R

6

Remove air filter housing

AR09.10-P-1150TS

7

Remove ME-SFI [ME] control unit (N3/10)

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273

AR07.08-P-7008TS

Model 211.057/257, 219.357

AR07.08-P-7008TX

8

Remove poly-V belt (3) and poly-V belt tensioning device

AR13.20-P-0001TS

9

Remove expansion reservoir (4)

Model 211 with engine 272, 273

AR46.25-P-1000TS

Model 219 with engine 272, 273

AR46.25-P-1000TX

10

Remove oil filter housing (5) with oil-water heat exchanger

AR18.20-P-3471TS

11

Remove front cover (6) at left cylinder head (7)

AR01.30-P-5700TS

 Installation: After installation of front cover (6), check that position of camshafts is at a 55° crank angle before top dead center (ignition TDC).

Refer to:



Check basic position of camshafts

AR05.20-P-6010TS

 Socket wrench bit

*001589650900

12

Remove ignition coils at left cylinder head (7)

AR15.12-P-2003TS

13

Remove oil separator (8)

AR01.20-P-9750TS

14

Remove resonance intake manifold (10)

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273

AR09.20-P-1961TS

Model 211.057/257, 219.357

AR09.20-P-1961TX

15

Remove left cylinder head cover (9)

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273

AR01.20-P-5014TS

Model 211.057/257, 219.357

AR01.20-P-5014TX

16

Remove alternator

AR15.40-P-5032TS

17

Rotate engine at crankshaft center bolt in direction of engine rotation to a 40° crankshaft angle after ignition TDC

AR05.20-P-6010-01VB

 Pay attention to position of camshafts.

 Socket wrench bit

*001589650900

18

Remove chain tensioner

Model 211, 219 with engine 272Chain tensioner with thread M241.5

AR05.10-P-7800TS

Model 211, 219 with engine 272, 273Chain tensioner with thread M221.5

AR05.10-P-7800VB

 Installation:
Replace chain tensioner with thread M221.5: The previously installed chain tensioner must not be reinstalled.
To remove the chain tensioner its thrust bolts are pressed into the end position and the lock on the thrust bolt prevents it moving back, whereby the timing chain would be overtensioned when being reinstalled.

 Model 211, 219 with engine 272Left cylinder head
Both chain tensioners can be installed.

 Model 211, 219 with engine 273Left cylinder head
Only the chain tensioner with thread M221.5 is installed.

19

Remove both camshaft adjuster (11) at left cylinder head (7)

AR05.20-P-7201TS

20

Remove air shutoff valve (12) at left cylinder head (7)

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273Left cylinder head

AR14.30-P-7200TS

21

Remove intermediate flange (12a) of air shutoff valve (12)

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273Left cylinder head

 Screw/bolt, left air shutoff valve intermediate flange to cylinder head

*BA14.30-P-1004-02A

22

Detach coolant hose (13) from heater valve

23

Disconnect electrical connection at coolant temperature sensor (B11/4)

24

Pull out slide rail pins (14) from left cylinder head (7)

Pull out guide rail pins at cylinder head

AR01.30-P-5800-04V

 Installation: Apply sealant to slide rail pins (14) before inserting them.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Impact extractor

*116589203300

 Threaded bolt

*116589013400

 Application gun

*112589002500

25

Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them

Tightening specifications for cylinder head bolts
Engine 272 in model 211, 219

AR01.30-P-5800-07VA

Tightening specifications for cylinder head boltsEngine 273 in model 211, 219

AR01.30-P-5800-07SX


The cylinder head bolts must only be loosened for a cooled engine.
Stresses can occur in the cylinder head (7) otherwise.

 Screw/bolt, cylinder head to timing case

*BA01.30-P-1003-01O

 Bolt, cylinder head to crankcase

*BA01.30-P-1016-01O

26

Remove LH cylinder head (7) from cylinder crankcase (1)

Topical note

Information on applying sealant to cylinder head gasket

AH01.30-P-1000-04RX

 Installation: Fit new cylinder head gasket (15) on the cylinder crankcase (1). Pay attention to fitting sleeves for fixing cylinder head (7).



Clean

27

Clean sealing surfaces on LH cylinder head (7), timing case cover and cylinder crankcase (1)

AR01.00-P-0050-01A

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

 Blow out threaded holes of cylinder head bolts in cylinder crankcase (1) with compressed air and clean off engine oil and coolant.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A



Check

28

Check cylinder head bolts and replace if necessary

AR01.30-P-5800-03VA

Cylinder head bolt

*BE01.30-P-1001-04B

29

Check sealing surfaces on LH cylinder head (7), timing case cover and cylinder crankcase (1) for cracks and unevenness


The cylinder head (7) and cylinder crankcase (1) must not be reworked (surface grinding).
The permissible machining tolerances will be exceeded otherwise. In the event of a complaint, replace cylinder head (7), timing case cover or cylinder crankcase (1).

 Any distortion of the cylinder head (7) occurring in the longitudinal or transverse direction will be balanced out again during reassembly through tightening of the cylinder head bolts.

30

Install in the reverse order

31

Change engine oil and oil filter element



Model 211, 219 with engine 272

AP18.00-P-0101PIT



Model 211, 219 with engine 273

AP18.00-P-0101SX

 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

32

Carry out an engine test run, and check engine and fuel system for leak tightness

33

Check cooling system for leaktightness

AR20.00-P-1010TS

Cylinder head/cylinder head bolts

Number

Designation

Engine 272

Engine 273

BE01.30-P-1001-04B

Cylinder head bolt

Thread diameter

M

11

11

Length (L) when new

mm

170

170

Length (L)

mm

172

172

For picture, see

-

-

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1003-01O

Screw/bolt, cylinder head to timing case

M8

Nm

20

20

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1016-01O

Bolt, cylinder head to crankcase

M11

Stage 1

Nm

20

20

Stage 2

Nm

50

50

Stage 3

°

90

90

Stage 4

°

90

90

 Air shutoff valve

Number

Designation

Engine 272

Engine 273

BA14.30-P-1004-02A

Screw/bolt, left air shutoff valve intermediate flange to cylinder head

Nm

14

14

 Exhaust system

Number

Designation

Engine 272 in model 219

Engine 273 in model 219

BA49.10-P-1001-01R

Screw/bolt, catalytic converter to exhaust manifold

Nm

20

20

 Exhaust system

Number

Designation

Engine 272, 273 in model 211

BA49.10-P-1001-01T

Bolt, catalytic converter to exhaust manifold

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

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