Remove/install cylinder head

AR01.30-P-5800VA

Remove/install cylinder head

20.3.12

8.2.11

Value changed: screw/Only pour fuels into suitable and appropriately marked containers cylinder head to timing case

*BA01.30-P-1003-01O

Value changed: Screw/bolt, catalytic converter to exhaust manifold

*BA01.30-P-1016-01O

 

Remove/install

Danger!

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

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

AS00.00-Z-0010-01A

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

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

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Open engine hood

 Only close engine hood after carrying out a leaktightness check.

AR88.40-P-1000V

 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

2

Disconnect ground line from battery

AR54.10-P-0003V



Notes on battery

AH54.10-P-0001-01A

3

Raise vehicle

AR00.60-P-1000V

4

Remove lower engine compartment paneling

 Installation: Do not install engine compartment paneling until after leak test.

AR61.20-P-1105V

 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

5

Drain coolant at radiator and at crankcase

AR20.00-P-1142VA



Notes on coolant

AH20.00-N-2080-01A

6

Detach right catalytic converter (1) from exhaust manifold



*BA49.10-P-1001-01N

7

Remove circuit 50 (2) from starter and detach cable from bracket



*BA15.30-P-1002-01J

8

Lower vehicle

9

Remove air filter housing

AR09.10-P-1150VA

10

Remove injection system control unit

AR07.08-P-7008VA

11

Remove fan shroud

AR20.40-P-6800VA

12

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

13

Remove resonance intake manifold

AR09.20-P-1961VA

14

Remove aspirator shutoff valve at the right cylinder head (6)

AR14.30-P-7200VA

15

Remove front cover on the right cylinder head (6)

 Installation: After fitting the front cover check the position of the camshafts at 55° crankshaft angle after ignition TDC, see:



AR01.30-P-5700VA

Check basic position of camshafts.

AR05.20-P-6010VA

16

Remove ignition coil on right cylinder head (6)

AR15.12-P-2003VA

17

Remove the right cylinder head cover

AR01.20-P-5014VB

18

Remove poly-V belt

AR13.22-P-1202VA

19

Remove upper guide pulley for poly-V belt

AR13.21-P-3350VA

20

Remove alternator

AR15.40-P-5032VA

21

Crank engine at center bolt for crankshaft to a 40° crank angle ATDC

 Observe position of camshafts:


Check basic position of camshafts.

AR05.20-P-6010-01VB



*001589650900

22

Remove chain tensioner

M241.5

AR05.10-P-7800VA

M221.5

AR05.10-P-7800VB

 Installation: Install new chain tensioner with thread of M221.5. The previously installed chain tensioner must not be reinstalled because during removal, its pressure pin is pressed into the end position. The thrust pin latch prevents this return stroke. This would overstretch the timing chain on reinstalling.

23

Remove camshaft adjuster on right cylinder head (6)

AR05.20-P-7201VA

24

Pull out slide rail bolt (6) at right cylinder head

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

AR01.30-P-5800-04V



*116589203300



*116589013400



*112589002500

Loctite 5970 sealant

*BR00.45-Z-1013-01A

25

Remove air pump with bracket.

AR14.30-P-7251VA

26

Remove screw/bolt (3) from oil dipstick guide tube



*BA01.45-P-1006-01M

27

Loosen cylinder head bolts in stages and remove them

 In order to avoid stresses in cylinder head (6), loosen cylinder head bolts when the engine has cooled down, in the reverse order of the tightening instructions: 

Tightening specifications for cylinder head bolts

AR01.30-P-5800-07VA

 The cylinder head bolt (4) at the rear left cannot be removed. To be able to handle the cylinder head (6) more easily, raise the cylinder head bolt (4) and fix it with a cable tie (5).



*BA01.30-P-1016-01O



*BA01.30-P-1003-01O

28

Remove right-hand cylinder head (6) from cylinder crankcase

 Installation: Insert left rear cylinder head bolt (4) in the cylinder head (6)before mounting the cylinder head (6) and fix in place with a cable tie (5).

 Installation: Pay attention to dowel sleeves (6) for locating and securing cylinder head.



Information on applying sealant to cylinder head gasket

AH01.30-P-1000-04RX

29

Check cylinder head bolts and replace if required

AR01.30-P-5800-03VA

Cylinder head bolt

*BE01.30-P-1001-04B



Clean

30

Clean threaded holes as well as sealing surfaces of right cylinder head (6), the timing case cover and the cylinder crankcase

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

AR01.00-P-0050-01A

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

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

31

Check contact surfaces of the right-hand cylinder head (6), the timing case cover and the cylinder crankcase for cracks and unevenness

 The cylinder head (6) and cylinder crankcase must not be post-worked (surface grinding). The permissible manufacturing tolerances may be exceeded otherwise. For a complaint about the cylinder head (6), replace the timing case cover or cylinder crankcase.

 Any distortion of the cylinder head (6) occurring in a longitudinal or transverse direction will be compensated for again during reassembly by tightening the cylinder head bolts.

32

Install in the reverse order

33

Carry out engine oil and filter change



Engine - oil and filter change

AP18.00-P-0101VA

 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

34

Check for oil leaks with engine running

35

Check fuel system for leaks with engine running

36

Inspect cooling system for leaks

AR20.00-P-1010V

Number

Designation

Engine
272

BE01.30-P-1001-04B

Cylinder head bolt

Thread diameter

M

11

Length (L) when new

mm

170

Length (L)

mm

172

See picture

-

Number

Designation

Engine
272
in model
171

BA49.10-P-1001-01N

Screw/bolt, catalytic converter to exhaust manifold

Nm

20

Number

Designation

Engine
272, 273

BA15.30-P-1002-01J

Nut, connection for circuit 50

Nm

8

Number

Designation

Engine 272

BA01.45-P-1006-01M

Mounting bolt for oil dipstick guide tube

Nm

9

Number

Designation

Engine
272

BA01.30-P-1003-01O

Cylinder head bolt on timing case

M8

Nm

20

BA01.30-P-1016-01O

Bolt, cylinder head to crankcase

M11

Stage 1

Nm

20

Stage 2

Nm

50

Stage 3

°

90

Stage 4

°

90

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite 5970 sealant

A 003 989 98 20

BR00.45-Z-1038-04A

Loctite 7200

Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de

BR00.45-Z-1046-04A

Loctite 7063 cleaning spray (150 ml)

A 001 986 71 71 10