Remove/install cylinder head

AR01.30-P-5800FG

Remove/install cylinder head

10.11.11

 

Remove/install

1

Remove water collector

AR83.25-P-1402FF

2

Remove engine hood

AR88.40-P-3000FF

3

Drain coolant

AR20.00-P-1142FG

4.1

Remove catalytic converter (4)

On vehicles without code (K13) Diesel particulate filter

AR49.10-P-5500FG

4.2

Remove catalytic converter diesel particulate filter unit

On vehicles with code (K13) Diesel particulate filter

AR49.10-P-5501FF

5

Remove alternator

AR15.40-P-5032FG

6

Remove air filter housing

AR09.10-P-1150FG

7

Remove cylinder head cover

AR01.20-P-5014FG

8

Detach oil return line (14) at turbocharger (13)

AR09.40-P-6020-06FG



*BA09.40-P-1001-01I

9

Undo screw/bolts (11) and remove bracket (12)

10

Unscrew screw/bolts (5) from exhaust manifold shield (6)

11

Detach air hoses at turbocharger (13)

12

Pull out vacuum line to vacuum reservoir (26) of turbocharger (13)

13.1

Remove refrigerant compressor connector (A9x1) at the refrigerant compressor (A9)

Only on vehicles with code (I01) Air conditioning Plus or Code (I77) Manual AC

14

Remove screws/bolts (17)



*BA20.10-P-1003-01R

15

Unscrew screw/bolt (18) at bracket of exhaust gas recirculation cooler (20)



*BA14.20-P-1002-01H

16

Unscrew screw/bolts (15) at mixing chamber (16)



*BA14.20-P-1001-01H

17

Pull out connection fittings (21) out of exhaust gas recirculation cooler (20)

 Installation: Replace gasket at connection fitting (21).

18

Disconnect coolant hose (19) at charge air manifold

 Installation: Ensure that the coolant hose (19) is correctly seated at the charge air distribution pipe.

19

Unscrew screw/bolts (1) at coolant pipe (2)

20

Disconnect engine wiring harness at engine (3)

AR01.00-P-2420-01FG

21

Remove camshaft sprocket

 Secure timing chain (8) in appropriate position using a cable tie to prevent timing chain (8) from falling.

AR05.20-P-6040FG

22

Remove inlet camshaft (9)

AR05.20-P-6292FG

23

Remove exhaust camshaft (10)

AR05.20-P-6292FH

24

Position engine mount bracket (24) and secure to engine with two Screw/bolts

 Use removed nuts.

25

Lower engine using vehicle jack

 Use suitable wooden or rubber supports, otherwise the oil pan can be damaged.

Ensure that the jack is securely positioned to prevent it from slipping.

26

Unscrew cylinder head bolts (25) and screw/bolts (22, 27)

 In order to avoid stresses in the cylinder head (23), loosen cylinder head bolts (25) and Screw/bolts (22, 27) in the reverse order of the tightening instructions.
Replace cylinder head bolts (25).

 Installation: Tighten cylinder head bolts (25) and Screw/bolts (22, 27) according to the sequence of the tightening pattern.

Tightening specifications for cylinder head bolts

AR01.30-P-5800-07FG



*BA01.30-P-1001-01R



*BA01.30-P-1002-01R



*BA01.30-P-1009-01R

27

Remove cable tie from timing chain (8), raise cylinder head (23) and guide timing chain (8) from the bottom out of the cylinder head (23)

 Carefully place cylinder head (23) onto a suitable support, otherwise the slide rail of the timing chain (8) can be damaged.

 Aid of 2 helpers required.
Do not allow timing chain (8) to fall out.

 Installation: Align cylinder head (23) using the guide sleeves (arrows) in the crankcase (29).

28

Remove the cylinder head gasket (28) and prevent the timing chain (8) from falling out

 Installation: Replace cylinder head gasket (28).

Align cylinder head gasket (28) using guide sleeves (arrows) in the crankcase (29).

29

Check tapped holes for cylinder head bolts (25) in crankcase (29) for contamination; clean if necessary

30.1

Reinstall detachable body components of cylinder head (23)

When replacing the cylinder head (23).



Checking

31

Clean sealing surfaces on the cylinder head (23) and crankcase (29) and check for visible damage

32

Inspect flatness of cylinder head (23)

 An uneven sealing surface of cylinder head (23) can lead to leaks in the area of cylinder head gasket (28).

AR01.30-P-5800-12FF

*BE01.30-P-1001-02F

Straightedge

33

Inspect crankcase (29) for flatness

 An uneven sealing surface of crankcase (29) can lead to leaks in the area of cylinder head gasket (28).

AR01.40-P-9133-01FF

*BE01.40-P-1001-02I

Straightedge

34

Install in the reverse order

35

Inspect cooling system for leaks

AR20.00-P-1010FG

 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

36

Perform engine test run and check engine around cylinder head (23) for leaks

37

Check engine oil level, correct if necessary

 Engine oil level must lie between the markings 'Min' and 'Max'; otherwise, engine damage may occur.

38

Read out fault memory, erase if necessary



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04FF

STAR DIAGNOSIS diagnosis system

Number

Designation

Engine 639.939

BE01.30-P-1001-02F

Permissible variation of flatness of lower separating surface

over the entire length

mm

0.03 to 0.2

Number

Designation

Engine 639.939

BE01.40-P-1001-02I

Crankcase flatness of separating surface

over the entire length

mm

0.05 to 0.1

Number

Designation

Engine 639.939

BA01.30-P-1001-01R

Torx bolt connecting cylinder head to crankcase

Stage 1

Nm

10

Stage 2

Nm

80

Stage 3

°

90

Stage 4

°

90

BA01.30-P-1002-01R

Torx bolt connecting cylinder head to timing case

Nm

20

BA01.30-P-1009-01R

Screw/bolt, cylinder head to crankcase

Nm

20

Number

Designation

Engine
639.939

BA09.40-P-1001-01I

Torx bolt connecting oil return line to turbocharger

Nm

7.6

Number

Designation

Engine
639.939

BA14.20-P-1001-01H

Screw/bolt connection fitting to mixing chamber

Nm

8

BA14.20-P-1002-01H

Screw/bolt exhaust gas recirculation pipe to charge air distribution housing

Nm

12

Number

Designation

Engine
639.939

BA20.10-P-1003-01R

Torx bolt connecting coolant temperature controller to charge air duct housing

Nm

14