Remove/install cylinder head - AR01.30-P-5800HA

ENGINES 605, 606 in MODEL 124 

ENGINE 606.961 in MODEL 140 

ENGINES 604, 605 in MODEL 202 

ENGINES 604, 605, 606.912 /962 in MODEL 210 

Fig 1: Identifying Cylinder Head Components (1 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cylinder Head Components (2 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Cylinder Head Components (3 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Cylinder Head Components (4 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
1	Disconnect battery ground cable		AR54.10-P-0003A
2	Remove engine compartment paneling
3	Drain/fill in coolant		AR20.00-P-1142HW
4.1	Remove radiator	Engine 606.962	AR20.20-P-3865HB
5	Remove poly-V-belt		AR13.22-P-1202HA
6	Remove cylinder head cover		AR01.20-P-5014HA
7.1	Remove intake manifold	Engines 604, 605.910/912, 606.910/912	AR09.20-P-1310H
8.2	Remove resonance intake manifold	Engine 606.912	AR09.20-P-1961H
9.3	Remove charge air distribution pipe	Engines 605.960/962	AR09.41-P-1310H
		Engine 606.961/962	AR09.41-P-1310HA
10	Detach coolant hoses (12) at cylinder head	Inspect condition of hose clamps and hoses, replace if necessary.	*WH58.30-Z-1001-06A  *WH58.30-Z-1002-06A
11.1	Detach vacuum lines (13) at cylinder head, mark if necessary	except 606.961/962
12	Unbolt exhaust system (6) at exhaust manifold or turbocharger	Exhaust manifold remains attached at cylinder head
13	Remove chain tensioner (20)		AR05.10-P-7800HA
14	Remove slide rail (33) in cylinder head Installation:  Install slide rail in such a way that the two mounting holes for the slide rail bolts point upwards (arrow) and the open side of the slide rail points counter to the direction of travel.		AR05.10-P-8432HA
15	Remove camshaft housing (22)		AR05.20-P-6995HA
	Bolts for attaching camshaft housing to cylinder head discontinued		BT05.20-P-0001-01A
16.1	Remove injection nozzles (23)	If cylinder head is replaced	AR07.03-P-6830H
	Risk of explosion  caused by ignition of flammable products, risk of poisoning  caused by inhaling fuel vapors or swallowing fuel as well as risk of injury  to skin and eyes exposed to 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
17	Detach fuel lines	Open fuel filler cap. Model 202: Detach fuel lines 90/1, 90/2 at the fuel preheater. Models 124, 140, 210: Disconnect the feed lines at the body and fit together with a section of hose.
18	Disconnect engine wiring harness (29) at cylinder head
19.1	Remove oil filter (40)	On models fitted with oil-water heat exchanger at oil filter	AR18.20-P-3471HA
20	Unbolt fuel filter (70/2) at cylinder head	Place fuel filter to the side with lines connected
21	Unscrew bolts (15) of cylinder head at timing case cover		*BA01.40-P-1002-01A
22	Unbolt pressure oil line (42), oil return flow line (43), charge air pipe (44) at turbocharger (41)	Engines 605.960/962, 606.961/962 Installation:  Replace gaskets and O-rings.
23	Slacken cylinder head bolts (16, 16a) in stages, unscrew	With the engine cool, loosen the cylinder head bolts in the reverse order to the bolt tightening pattern.
			Fig 5
		Tightening pattern of cylinder head bolts Installation:  It is not necessary to re-tighten the cylinder head bolts. Oil thread and head contact surface of cylinder head bolts, insert, tighten in stages	AR01.30-P-5800-01HA
			*BA01.30-P-1002-01A
24	Inspect cylinder head bolts (16, 16a)		AR01.30-P-5800-03HA  *BE01.30-P-1001-04A
25	Bolt on bracket (17) for removing cylinder head	Screw bracket onto first and last camshaft bearing (at exhaust side) using bolts (19) M7x35.
			Fig 6
26	Remove cylinder head (02)	Installation:  Lay new cylinder head gasket (25) onto crankcase. When remounting the top, align with fitted bushings (26) for lining up the cylinder head. If the crankcase has been machined, a repair size cylinder head gasket with a thickness of 1.85 mm must be installed, if necessary  ↓
		Measure piston projection If timing case cover and cylinder head are removed at the same time, the setting of the injection pump is altered; check start of delivery, set if necessary ↓	AR03.10-P-7041-01A
		Model 124	ra07016058300x
		Models 140, 202, 210	AD07.00-P-1464B
			*WE58.40-Z-1012-11A
	Technical modification to cylinder head gasket		BT01.30-P-0001-01A
27	Clean contact surfaces (24) and threaded holes	Blow out threaded holes, free of oil and water, inspect contact surfaces, if necessary ↓
		Machining crankcase contact surface	AR01.40-P-9133B
		Check/face grind cylinder head contact surfaces	AR01.30-P-7162B
28.1	Remove oil from cooling and heating system	If oil residues in cooling and heating system	AR20.00-P-1250A
29	Install in the reverse order
30	Inspect cooling system for leaks		AR20.00-P-1010HA
31	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 running engine Run engine and inspect for leaks	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
32	Read fault memory, erase.	Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed.	AD00.00-P-1000AZ

Cylinder head tightening torques

Crankcase, timing case cover, end cover

Fig 5: Identifying (601 589 00 10 00) Screwdriver Bit

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying (119 589 01 40 00) Retaining Clip

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.