Remove/install cylinder head

AR01.30-P-5800MFE

Remove/install cylinder head

18.02.2020

Engine

608 in model 118, 177, 247

Modification notes

25.10.2019

Document completely revised.

1

Camshaft

6

Cylinder head bolts

2

Clutch

7

Coolant thermostat

4

Coolant hose

9

Screw

5

Coolant hose

10

Cylinder head

2

Clutch

3

Screw

4

Coolant hose

5

Coolant hose

7

Coolant thermostat

8

Screw

10

Cylinder head

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Notes on coolant level

AH20.00-P-1142-01CW

 

Remove/install

1

Remove camshaft (1).

AR05.20-P-6992MFE

 Installation: Only install upper engine cover and lower engine compartment lining after leak test.

2

Remove rail.

AR07.03-P-1010MFE

3

Remove fuel high-pressure pump.

AR07.02-P-1028MFE

4

Remove exhaust gas aftertreatment unit.

AR49.20-P-1500MFE

5

Remove oil return feed line of the exhaust gas turbocharger.

AR09.40-P-6021MFE

6

Release and disconnect coupling (2) and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Catch escaping coolant with a suitable container.

 Set of protective caps

*001589009100

7

Remove screw (3).

 Screw, coolant line clamp to coolant line

*BA20.20-P-1004-02C

8

Remove coolant hoses (4, 5) from the coolant thermostat (7) and seal openings with protective covers.

 Catch escaping coolant with a suitable container.

 Hose clamp pliers

*454589003700

 Set of protective caps

*001589009100

9

Remove screw (8).

 M61

*BA00.10-P-1002-04A

10

Remove screw (9).

 Bolt, coolant line to crankcase

*BA20.20-P-1003-02C

11

Remove Hall sensor of the camshaft (B6/1).

AR15.10-P-1999MFE

12

Remove cylinder head bolts (6) contrary to the tightening procedure.

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01ORA

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A


Loosen cylinder head bolts (6) only if the engine is completely cooled down.
The cylinder head (10) will otherwise be damaged.

 Installation: Pay attention to tightening procedure of the cylinder head bolts.

 Installation: Replace cylinder head bolts.

 Bolt, cylinder head to cylinder crankcase

*BA01.30-P-1001-01ZA

13

Remove cylinder head (10) from crankcase.

General information on checking camshafts and bearing points of camshafts

AH05.20-P-1000-09SZ

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

General information on checking valves, valve seats and valve guides

AH05.30-P-1000-02SZ

 Aid of helper required.

 Installation: Pay attention to the pilot bushings for fixing the cylinder head (10) in place.

14

Remove cylinder head gasket.

 Installation: Replace cylinder head gasket.



Clean

15

Clean sealing surfaces on cylinder head (10) and crankcase.

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
Otherwise, damage to the sealing surfaces can occur.

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

Loctite 7200

*BR00.45-Z-1038-04A

16

Cover threaded holes of the cylinder head bolts (6) in the crankcase with rags and blow out with compressed air.



Check

17

Check sealing surfaces of the cylinder head (10) and crankcase for cracks and unevenness.


Do not rework cylinder head (10) and crankcase (surface grinding).
The permissible production tolerances will otherwise be exceeded.

 Tightening the cylinder head bolts (6) compensates for a slight distortion of the cylinder head (10) in the longitudinal or transverse direction.

 Straightedge

*452589019924

If cracks or unevenness are present,



replace cylinder head (10) and crankcase.

18

Install in the reverse order.

Concluding tasks

19

Change engine oil and filter element.



AP18.00-P-0101MFD

 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

20

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

21

Install lower engine compartment lining.

AR61.20-P-1105MFE

22

Install upper engine cover.



AP01.10-P-2405-01B

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Tightening torques, cylinder head

Number

Designation

Engine 608

BA01.30-P-1001-01ZA

Bolt, cylinder head to cylinder crankcase

M11

Stage 1

Nm

25

Stage 2

°

270

 Engine radiator, coolant hoses and lines

Number

Designation

Engine 608

BA20.20-P-1003-02C

Bolt, coolant line to crankcase

M6

Nm

10

 Engine radiator, coolant hoses and lines

Number

Designation

Engine 608

BA20.20-P-1004-02C

Screw, coolant line clamp to coolant line

M6

Nm

8

Repair materials

Number

Designation

Order number

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