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

ENGINE 601 in MODEL 124, 201, 202

ENGINE 602 in MODEL 124, 201

ENGINE 603 in MODEL 124, 126, 140

Fig 1: Identifying Cylinder Head Remove/Install Components - Engine 601 In Model 124, 201, 202 (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cylinder Head Remove/Install Components - Engine 601 In Model 124, 201, 202 (2 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

1.1.91

Cylinder head bolts changed

Refer to Step 24

BT01.30-P-0003-01A

	Remove/install
	Remove cylinder head only once the engine has cooled off
1	Remove camshaft		ra05006010220x
		Installation: Check basic position of camshaft	AR05.20-P-6010HW
2	Remove nozzle holder	On naturally aspirated engine	ra07016010230x
		On turbocharged engine	ra07016026810x
3	Remove radiator	Models 124, 126, 140, 201	AR20.20-P-3865HW
		Model 202	AR20.20-P-3865HA
4	Remove poly V-belt		AR13.25-P-3200HW
5	Pinch-off ground line at battery (120)		AR54.10-P-0003A
6.1	Remove air intake hose (11) and air cleaner cover (10) with filter insert	Naturally aspirated engine
7.1	Detach cover (3, 7)	Model 140
8.1	Detach intake hose (1) to turbocharger	On turbocharged engine
9.1	Unscrew supporting strut (155) of heater return line	On turbocharged engine
10.1	Unscrew pressure oil line charger to cylinder crankcase	On turbocharged engine	ra09006026020x
11	Detach fuel filter (12)
		For this step pinch off fuel line and unbolt bolts to cylinder head.
12	Unbolt bracket (62) of oil dipstick guide tube
13.1	Detach pipe line (6) between exhaust gas recirculation valve and intake manifold or charge air distribution pipe	For engine fitted with exhaust gas recirculation
14.1	Detach exhaust gas recirculation (13) line to air guide housing	For engine fitted with exhaust gas recirculation
15	Unbolt exhaust side support (5) at transmission
16	Unscrew exhaust pipe (4) from exhaust manifold	On naturally aspirated engine	ra49006010100x
		On turbocharged engine	ra49006027000x
17.1	Remove manifold of heater feed at rear left cylinder head	For engines fitted with exhaust gas recirculation Installation: Replace O-ring
18	Unscrew glow plug connection line (9)
19.1	Unplug connector (X26/2)	Model 202
20	Remove intake manifold (8) on naturally aspirated engine or charge air distribution pipe on turbocharged engine	On naturally aspirated engine	ra14006010180x
		On turbocharged engine	ra14006021310x
21	Knock out slide rail pins (221, 222) at cylinder head	Installation: Coat collar of sliding rail pins with sealing mass.	AR01.30-D-5800-04B
			Figure
			Figure
			Fig 5 *BR00.45-Z-1009-01A
22	Take slide rail (15) of timing chain out of chain case
23	Unscrew hexagon socket head screws (16) in chain case		*BA01.40-P-1002-01A
	Cylinder head bolt changed		BT01.30-P-0003-01A
24	Unscrew cylinder head bolts (17, 18, 19) in reverse order of tightening pattern		Fig 6
		Loosening/tightening pattern Installation: Check length and if necessary use new cylinder head bolts. Observe different bolt length and tightening instructions. Oil thread and bolt head contact surface before assembling	AR01.30-P-5800-01HW
			AR01.30-P-5800-03HA *BE01.30-P-1001-04A
			*BA01.30-P-1003-01C
25	Remove cylinder head (20) together with cylinder head gasket (21)	Clean separating surfaces and check for cracks. Install cylinder head together with new seal.
26	Clean threaded holes of cylinder head bolts	blow out with compressed air
27.1	Remove oil from cooling and heating system	If oil present in cooling and heating system	ra20006010016x
28.1	Remove overflow tank and clean	If oil present in cooling and heating system
		Engine 602.96 in Model 124, 201 Engine 603.96 in Model 124	AR20.30-P-4540HW
		Engine 603 in Model 140	AR20.30-P-4540HX
29	Install in the reverse order
30	Check engine oil level, adjust to correct level.
31	Inspect cooling system for leaks		AR20.00-P-1010HA
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns when working in engine during starting procedure	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
32	Run engine and inspect for leaks
33	Read fault memory, erase		AD00.00-P-1000AZ

CYLINDER HEAD/CYLINDER HEAD BOLTS

Number	Designation			Engines 601, 602 except 602.98, 603
BE01.30-P-1001-04A	Cylinder head bolt	Thread diameter	M	10
		Length (L) when new	mm	80/102/115
		max. length (L)	mm	82/104/117
		Fig. see		-

CYLINDER HEAD TIGHTENING TORQUES

Number	Designation			Engine 601	Engine 602 except 602.98
BA01.30-P-1003-01C	Cylinder head bolt M10	1st stage	Nm	15	15
		2nd stage	Nm	35	35
		Step 3	∠ °	90	90
		Settling time	min	10	10
		4th stage	∠ °	90	90
		Fig. see		-	-

CYLINDER HEAD TIGHTENING TORQUES

Number	Designation			Engine 603
BA01.30-P-1003-01C	Cylinder head bolt M10	1st stage	Nm	15
		2nd stage	Nm	35
		Step 3	∠ °	90
		Settling time	min	10
		4th stage	∠ °	90
		Fig. see		ra01006010415x

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation		Engine 601, 602 except 602.98, 603
BA01.40-P-1002-01A	Bolt of cylinder head to timing case cover	Nm	25

Fig 3: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Threaded Pin (116 589 01 34 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Extractor (605 589 00 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Screwdriver Bit (601 589 00 10 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1009-01A	Sealant	A 001 989 89 20