Remove/install cylinder head - AR01.30-P-5800GZ (ML500): Notes

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ENGINE 113.964 in MODEL 164.175

Fig 1: Identifying Cylinder Head Remove/Install Components - Engine 113.964 (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cylinder Head Remove/Install Components - Engine 113.964 (2 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the four pillars of the hoist and position the four support plates at the hoist mounting points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. 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
	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 contact with fuel.	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
	Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Detach ground line on battery	Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery. Vehicles with Keyless Go, code 889: Switch off engine, remove Keyless Go cards from the vehicle and keep outside the range of the transmitter.	AR54.10-P-0003GZ
	Notes on battery	All models	AH54.10-P-0001-01A
2	Remove bottom engine compartment paneling		AR61.20-P-1105GZ
3	Drain coolant from radiator		AR20.00-P-1142GZ
4	Remove engine trim panel		AR01.10-P-2405GZ
5	Remove hot film mass air flow sensor (B2/5) with air intake tube		AR07.07-P-1454GZ
6	Reduce fuel pressure with the pressure hose via the service valve		AR07.03-P-1460-01GZ
		Pressure hose	Fig 3
7	Dismount fuel feed line at fuel distributor	Intercept the escaping fuel with an absorbent rag!
			*BA07.52-P-1001-01A
8	Remove ignition coil of cylinders 1 to 4 (T1/1-T1/4) and ignition coil of cylinders 5 to 8 (T1/5-T1/8)		AR15.12-P-2003GZ
9	Remove the right cylinder head cover (7) and the left cylinder head cover (9)		AR01.20-P-5014GZ
10	Remove air pump		AR14.30-P-7251GZ
11	Remove intake manifold (13)	Installation: On vehicles with engine damage, the intake manifold (13) must be examined by means of a visual inspection for metal debris before assembly. Any metal debris present must be removed, otherwise engine damage could reoccur.	AR09.20-P-1310GZ
12.1	Remove camshaft Hall sensor (B6/1)	Only when removing from right cylinder head (23).	AR15.10-P-2000GZ
13.1	Remove poly-V-belt (3)	Only when removing from left cylinder head (22).	AR13.22-P-1202GZ
14	Remove coolant line (15) of left cylinder head (22) at firewall	Latch retaining spring using a screwdriver into the fixture marking and remove the coolant line. Installation: Install new O-ring. Before installing the coolant line, insert retaining spring in the basic position.
15	Disconnect exhaust system from exhaust manifold	Installation: On vehicles with engine damage it is necessary to inspect the exhaust system for metal debris before installing it and to remove any metal debris present, otherwise this might result in damage to the catalytic converter system.	*BA14.10-P-1002-01B
16	Rotate the engine at the center bolt of the crankshaft in the direction of rotation up to 40° crank angle after ignition TDC at the first cylinder	Do not reverse crank the engine. The groove at the camshaft must point the direction "Inwards-F".
17	Lock camshaft using locating plate	Right plate: ↓
		Locating plate	Fig 4
		Left plate: ↓
		Locating plate	Fig 5
18.1	Remove screws from oil cleaner housing with oil-water heat exchanger (18)	Only when removing from left cylinder head (22).	AR18.30-P-3481GZ
19	Remove chain tensioner (12)	Lay alternator (G2) with attached lines to one side.	AR05.10-P-7800GZ
20	Remove camshaft sprockets (16) from camshaft	When camshaft sprockets (16) are removed the engine must not be cranked any further otherwise the timing chain can skip a link and this can cause damage to occur.
		Open-end wrench	Fig 6
		Insertion tool	Fig 7
		Torque wrench	Fig 8
		Right-hand camshaft sprocket: Tie timing chain tight on camshaft sprocket with cable strap. Left-hand camshaft sprocket: Mark camshaft sprocket to timing chain and remove camshaft sprocket.
		Installation: Inspect basic position of camshafts.	AR05.10-P-6858GZ
		After inspecting, if necessary: ↓
		Set the basic position of camshafts.	AR05.20-P-6020GZ
			*BA05.20-P-1001-01B
21	Remove camshaft bearing bridges (17)		AR05.20-P-7103GZ
22	Remove bolts (20)		*BA01.40-P-1002-01C
23	Loosen cylinder head bolts (21) in stages and unscrew	When the engine has cooled off, loosen cylinder head bolts according to the loosening scheme otherwise the additional torque could exceed the elastic range of the cylinder head bolt.	AR01.30-P-5800-09B
		Installation: Observe tightening pattern and tightening instructions of cylinder head bolts so that distortion of the cylinder head does not arise. Oil thread and head contact surface of cylinder head bolts.	AR01.30-P-5800-07B
			*BA01.30-P-1001-01D
		Screwdriver insert	Fig 9
24	Take off cylinder head.	Installation: pay attention to dowel sleeves (26) for locating the cylinder head.
	Information on applying sealant to cylinder head gasket		AH01.30-P-1000-04V
	Information on cylinder head contact surface		AH01.30-P-1000-05A
	Information for assigning the cylinder head gaskets		AH01.30-P-1000-06V
		Sealant	*BR00.45-Z-1013-01A
25	Clean sealing surfaces of crankcase, cylinder head and tapped holes
	Checking
26	Check cylinder head bolts (21)		AR01.30-P-5800-03B
			*BE01.30-P-1001-04B
27	Check crankcase and cylinder head for cracks, void inclusions and flatness	Sealing surfaces of crankcase and cylinder head are provided with an 0.8 mm thick silicone layer during series production. At the time of repair installation, silicone sealant is applied to the sealing area only in case of any shrink holes. The sealant must be applied within 10 minutes!
		Sealant	*BR00.45-Z-1013-01A
28	Install in the reverse order
29	Inspect cooling system for leaks		AR20.00-P-1010GZ
	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	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
30	Conduct engine test run and check the engine for leaks while it is running	In the event of oil loss determine and eliminate cause, otherwise malfunctions, transmission damage, and serious environmental pollution may occur.
31	Read out fault memory and erase	Stored faults which may be caused by disconnecting cables or by simulation during test operations, must be erased in the fault memory after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnostic system	*WH58.30-Z-1048-13A

CYLINDER HEAD/CYLINDER HEAD BOLTS

Number	Designation			Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/987/988/ 990/991/992/ 993/995
BE01.30-P-1001-04B	Cylinder head bolt	Thread diameter	M	11
		Length (L) when new	mm	141.5
		Length (L)	mm	≤ 144.5
		See picture		AR01.30-P-5800-03B

CYLINDER HEAD

Number	Designation			Engine 113.964
BA01.30-P-1001-01D	Bolt, cylinder head to crankcase	Stage 1	Nm	10
		Stage 2	Nm	30
		Stage 3	∠°	90
		Stage 4	∠°	90

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation		Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992/995
BA01.40-P-1002-01C	Bolt, cylinder head to timing case cover	Nm	20

CAMSHAFT

Number	Designation				Engines 113.940/941/ 942/943/944/ 948/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992/995
BA05.20-P-1001-01B	Bolt, camshaft sprocket	M12X45	Stage 1	Nm	50
BA05.20-P-1001-01B	Bolt, camshaft sprocket	M12X45	Stage 2	∠°	90

FUEL RAIL

Number	Designation		Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/988
BA07.52-P-1001-01A	Disconnect fuel feed line at fuel rail	Nm	38

EXHAUST MANIFOLD

Number	Designation		Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992/993/ 995
BA14.10-P-1002-01B	Flange connection, exhaust manifold and front exhaust pipes	Nm	20

Fig 3: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Locating Plate (112 589 00 32 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Locating Plate (112 589 01 32 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Open End Wrench (112 589 00 01 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Insertion Tool (112 589 01 03 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Torque Wrench (001 589 72 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying Screwdriver Insert (000 589 03 10 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1048-13A	STAR DIAGNOSIS diagnostic system, Compact Passenger Car	6511 1801 00

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Sealant	A 003 989 98 20