Remove/install cylinder head - AR01.30-P-5800GZS (ML63 AMG): Notes

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ENGINE 156 in MODEL 164, 251

Fig 1: Identifying Cylinder Head Remove/Install Components - Engine 156 (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cylinder Head Remove/Install Components - Engine 156 (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 columns of vehicle lift and position four support plates at vehicle lift support points specified by 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 caused by 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 and 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
	Notes on avoiding damage to electronic components due to electrostatic discharge	All models	AH54.00-P-0001-01A
1	Turn key in ignition switch to position "0".
2	Open engine hood and raise to vertical position	Model 164	AR88.40-P-1000GZ
		Model 251	AR88.40-P-1000RT
	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 glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
3	Disconnect ground line of battery	Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery.	AR54.10-P-0003GZ
	Notes on battery	All models	AH54.10-P-0001-01A
4	Raise vehicle with lifting platform	Model 164	AR00.60-P-1000GZ
		Model 251	AR00.60-P-1000RT
5	Remove bottom engine compartment paneling	Installation: Only install bottom engine compartment paneling after engine test run.
		Model 164	AR61.20-P-1105GZ
		Model 251	AR61.20-P-1105RT
6	Drain coolant		AR20.00-P-1142GZS
7	Remove catalytic converter from exhaust manifold	according to which cylinder head (7) should be removed.
8	Remove the partition wall between the wheelhouses	Only model 251.	AR62.30-P-2400RT
9	Remove air filter housing	Lift front engine cover vertically upwards otherwise the retaining lugs can break off.	AR09.10-P-1150GZS
10	Remove spark plugs	Only if it is not possible to crank the engine due to the high compression.	AR15.12-P-1010GZS
11	Rotate engine at crankshaft center bolt in direction of rotation of the engine to a 40° crankshaft angle after top dead center (TDC)	Rotate engine at crankshaft in running direction until scribe mark 40° on pulley/vibration damper corresponds with scribe mark on timing case.
12	Remove electric fan		AR20.40-P-5000GZS
13	Remove intake manifold (1)		AR09.20-P-1961GZS
14	Remove poly V-belt (2)		AR13.22-P-1202GZS
15	Remove alternator (G2)	Lay alternator (G2) with connected lines in engine compartment.	AR15.40-P-5032GZS
16	Remove chain tensioner		AR05.10-P-7800GZS
	Left-hand side
17	Remove left cylinder head cover (4)		AR01.20-P-5014GZS
18	Remove intake camshaft adjuster (5) and exhaust camshaft adjuster (6) at left cylinder head (7)	Up to engine number 001177	AR05.20-P-7201ANG
		from engine number 001178	AR05.20-P-7201AMG
		Removal: Lock camshaft adjuster at rear using a bolt. Use retaining device (01) and associated straightedge to loosen camshaft adjuster. Installation: Observe identification for intake and exhaust camshaft adjusters. Lock camshaft adjuster with retaining device (01) and straightedge, see: ↓
		Check basic position of camshafts	AR05.20-P-6010AMG
			*BA05.20-P-1001-02J
		Retainer	Fig 3
19	Remove camshaft drive gear (8) at left cylinder head (7)		AR05.20-P-7201-07AMG
			*BA05.20-P-1003-02J
		Impact extractor	Fig 8
		Threaded stud	Fig 4
20	Remove camshafts		AR05.20-P-6992AMG
21	Remove combination valve (9)	Removal: Also unscrew air line (10) at cylinder head (7). Installation: Lay air line (10) inside before assembling cylinder head. Later assembly is only possible if the power steering pump is removed. Replace gasket.	AR14.30-P-7255GZS
22	Remove oil filter housing (11)		AR18.20-P-3471GZS
		Socket	Fig 7
23	Pull out slide rail pins from left cylinder head (7)		AR01.30-P-5800-04AMG
		Impact extractor	Fig 8
		Threaded stud	Fig 6
24	Loosen the cylinder head bolts in stages in the reverse order of the tightening procedure and remove them	To avoid stresses in cylinder head (7), cylinder head bolts must only be loosened when engine has cooled off, see: ↓
		Tightening specifications for cylinder head bolts	AR01.30-P-5800-07AMG
			*BA01.30-P-1002-01U
			*BA01.30-P-1003-01U
			*BA01.30-P-1008-01U
			*BA01.30-P-1009-01U
25	Remove cylinder head (7) from crankcase (12)	Installation: Place new cylinder head gasket (12) on crankcase. Pay attention to fitted sleeves for fixing cylinder head (7). The cylinder head bolts must always be renewed.
	Right-hand side
26	Remove right cylinder head cover (13)		AR01.20-P-5014GZS
27	Disconnect connector from coolant temperature sensor	The connector for the temperature sensor is located behind the power steering pump oil reservoir.
28	Remove intake camshaft adjuster (5) and exhaust camshaft adjuster (6) at right cylinder head (7)	Up to engine number 001177	AR05.20-P-7201ANG
		from engine number 001178	AR05.20-P-7201AMG
		Removal: Lock camshaft adjuster at rear using a bolt. Use retaining device (01) and associated straightedge to loosen camshaft adjuster. Installation: Observe identification for intake and exhaust camshaft adjusters. Lock camshaft adjuster with retaining device (01) and straightedge, see: ↓	AR05.20-P-7201AMG
		Check basic position of camshafts	AR05.20-P-6010AMG
			*BA05.20-P-1001-02J
		Locating plate	Fig 5
		Retainer	Fig 3
29	Remove camshaft drive gear (8) at right cylinder head (7)		AR05.20-P-7201-07AMG
			*BA05.20-P-1003-02J
		Impact extractor	Fig 8
		Threaded stud	Fig 4
30	Remove camshafts		AR05.20-P-6992AMG
	Remove right combination valve (14) for air pump	Removal: Only unscrew air line (15) at cylinder head (7). Installation: Install new gasket	AR14.30-P-7255GZS
31	Remove guide pulley (16)		*BA13.25-P-1004-01U
32	Pull rail pins and tensioning rail bolts from right cylinder head (7)		AR01.30-P-5800-04AMG
		Impact extractor	Fig 8
		Threaded stud	Fig 6
33	Loosen the cylinder head bolts in stages in the reverse order of the tightening procedure and remove them	To avoid stresses in cylinder head (7), cylinder head bolts must only be loosened when engine has cooled off, see: →
		Tightening specifications for cylinder head bolts	AR01.30-P-5800-07AMG
			*BA01.30-P-1002-01U
			*BA01.30-P-1003-01U
			*BA01.30-P-1008-01U
			*BA01.30-P-1009-01U
34	Remove cylinder head (7) from crankcase (12)	Installation: Place new cylinder head gasket (12) on crankcase. Pay attention to fitted sleeves for fixing cylinder head (7). Pay attention to maximum length of cylinder head bolts.
	Clean
35	Clean sealing surfaces at cylinder head (7) and at crankcase (12)	Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces. Blow out tapped holes of cylinder head bolts in crankcase (12) with compressed air, and clean off engine oil and coolant.
		LU cleaner	*BR00.45-Z-1028-04A
	Checking
36	Checking cylinder head bolts	If maximum length of cylinder head bolts is exceeded the bolts must be replaced.	AR01.30-P-5800-03AMG
		Cylinder head bolt	*BE01.30-P-1001-04B
37	Check sealing surfaces at cylinder head (7) and at crankcase (12) for cracks and unevenness	The cylinder head (7) and crankcase (12) must not be post-worked (face grinding) because production tolerances must not be exceeded.
38	Install in the reverse order
39	Change engine oil and oil filter element
	Engine - oil and filter change		AP18.00-P-0101GZ
40	Perform basic programming	Model 164	AR00.19-P-0200GZ
		Model 251	AR00.19-P-0200RT
	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
41	Carry out an engine test run, and check the engine and fuel system for leaks
42	Inspect cooling system for leaks		AR20.00-P-1010GZS
43	Perform new calibration of the sensor rotor for camshaft adjuster using STAR DIAGNOSIS	When removing the camshaft adjuster new calibration is always necessary.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

CYLINDER HEAD/CYLINDER HEAD BOLTS

Number	Designation			Engine 156
BE01.30-P-1001-04B	Cylinder head bolt	Thread diameter	M	11
		Length (L) when new	mm	175
		Length (L)	mm	176.2
		See picture		-

CAMSHAFT, CAMSHAFT ADJUSTMENT

Number	Designation			Engine 156
BA05.20-P-1001-02J	Bolt, camshaft adjuster to camshaft	M12	Nm	115
BA05.20-P-1003-02J	Bolt connecting bearing pin of camshaft drive gear to crankcase	M6	Nm	9

CYLINDER HEAD

Number	Designation				Engine 156
BA01.30-P-1002-01U	Bolt, cylinder head to crankcase		Stage 1	Nm	10
			Stage 2	Nm	50
			Stage 3	∠°	90
			Stage 4	∠°	90
			5th stage	∠°	90
BA01.30-P-1003-01U	Bolt, cylinder head to crankcase	M8		Nm	20
BA01.30-P-1008-01U	Cylinder head to timing case chain box on the outside	M8		Nm	20
BA01.30-P-1009-01U	Cylinder head to timing case chain box on the inside	M8		Nm	20

BELT TENSIONING DEVICE

Number	Designation		Engine 156
BA13.25-P-1004-01U	Guide pulley on coolant pump housing (between alternator and smooth guide pulley)	Nm	20

Fig 3: Identifying Holding Device (156 589 00 61 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Threaded Stud (156 589 00 34 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Locating Plate (156 589 00 32 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Threaded Stud (116 589 01 34 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Wrench Socket (001 589 65 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	LU cleaner	Adolf Wurth GmbH & Co. KG Reinhold-Wurth-Str. 12-17 74653 Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 www.wuerth.de

Fig 9: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 10: Identifying Threaded Stud (156 589 00 34 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 11: Identifying Wrench Socket (001 589 65 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.