Remove/install cylinder head

AR01.30-P-5800VB

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



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

1

Open engine hood

AR88.40-P-1000V

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only pour liquid battery electrolyte (diluted sulfuric 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 bottom engine compartment paneling

 Installation: Install bottom engine compartment paneling only after engine test run.

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

6

Detach left catalytic converter (2) at exhaust manifold



*BA49.10-P-1001-01N

7

Lower vehicle

8

Remove air filter housing

AR09.10-P-1150VA

9

Remove ME-SFI [ME] control unit

AR07.08-P-7008VA

10

Remove fan shroud

AR20.40-P-6800VA

11

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

12

Remove poly-V belt

AR13.22-P-1202VA

13

Remove poly-V belt tensioning device

AR13.25-P-3200VA

14

Remove oil filter housing with oil-water heat exchanger

AR18.20-P-3471VA

15

Remove power steering expansion reservoir

AR46.25-P-1000VA

16

Remove front cover on left cylinder
head (5)

 Installation: After installing the front cover the position of the camshafts should be checked at 55° crank angle before top dead center (TDC): 

AR01.30-P-5700VB

Check basic position of camshafts.

AR05.20-P-6010VA



*001589650900

17

Remove ignition coils at left cylinder
head (5)

AR15.12-P-2003VA

18

Remove oil separator

AR01.20-P-9750VA

19

Remove left cylinder head cover

AR01.20-P-5014VA

20

Remove resonance intake manifold

AR09.20-P-1961VA

21

Remove alternator

AR15.40-P-5032VA

22

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

23

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.

24

Remove camshaft adjuster for left cylinder head (5)

AR05.20-P-7201VA

25

Remove aspirator shutoff valve at left cylinder head (5)

AR14.30-P-7200VB

26

Remove intermediate flange (1) of air shutoff valve



*BA14.30-P-1004-02A

27

Detach coolant hose (3) from coolant connection (4) on the back of the left-hand cylinder head (5)

 The new cylinder head (5) is delivered without a coolant connection (4).

28

Pull off plug (8) from coolant temperature sensor on the back of the left-hand cylinder head (5)

29

Pull out guide pin of slide rail on left-hand cylinder head (5)

AR01.30-P-5800-04V



*116589203300



*116589013400

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



*112589002500

Loctite 5970 sealant

*BR00.45-Z-1013-01A

30

Loosen cylinder head bolts in stages and remove them

 To avoid stresses in cylinder head (5), cylinder head bolts must be loosened in the reverse order of the tightening instructions when the engine has cooled off:



Tightening specifications for cylinder head bolts

AR01.30-P-5800-07VA



*BA01.30-P-1003-01O



*BA01.30-P-1016-01O

31

Remove left-hand cylinder head (5) from cylinder crankcase

 Installation: Lay new cylinder head gasket (6) onto crankcase. Pay attention to fitted sleeves for fixing cylinder head (5).



Information on applying sealant to cylinder head gasket

AH01.30-P-1000-04RX

32

Check cylinder head bolts and replace if required

AR01.30-P-5800-03VA

*BE01.30-P-1001-04B



Clean

33

Clean sealing surfaces on left-hand cylinder head (5), cylinder crankcase and timing case cover

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 for cylinder head bolts in crankcase with compressed air, and clean off any engine oil and coolant.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

34

Check sealing surfaces on left cylinder head (5), cylinder crankcase and timing case cover for cracks and unevenness

 The cylinder head (5) 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 (5), replace the timing case cover or cylinder crankcase.

 Any distortion of the cylinder head (5) occurring in a longitudinal or transverse direction will be compensated for again during reassembly by tightening the cylinder head bolts.

35

Install in the reverse order

36

Change engine oil and oil filter element



Engine - oil and filter change

AP18.00-P-0101VA



Checking

 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

37

Carry out an engine test run, and inspect engine and fuel system for leaks

38

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, catalytic converter to exhaust manifold

Nm

20

Number

Designation

Engine
272

BA14.30-P-1004-02A

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

Nm

14

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