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Remove/install cylinder head - AR01.30-P-5800GZC: Notes

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ENGINES 642 in MODEL 211 

Fig 1: Identifying Cylinder Head Components
G07252919Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES

23.10.08 Remove/install high-pressure pump - added Step 8
23.10.08 Check basic position of camshaft - added Step 9
REMOVINGINSTALLING Remove/install     
DANGER 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
DANGER 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
DANGER Risk of explosion  caused by escaping oxyhydrogen gas. Risk of injury  caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries  caused by short circuit. Risk of poisoning  caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices No fire, sparks, open flames or smoking. Wear acid-resistant gloves and clothing and safety glasses with side guards. Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground. Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers. AS54.10-Z-0001-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
IMPORTANT Notes on assigning the cylinder head gaskets   AH01.30-P-1000-06PI 
1 Disconnect battery ground line   AR54.10-P-0003GZ
NOTES Notes on battery AH54.10-P-0001-01A
2 Drain and collect coolant from radiator   AR20.00-P-1142GZB
    NOTES Notes on coolant AH20.00-N-2080-01A
3 Remove strut tower brace Model 164.8 only AR62.30-P-2500GY
4 Remove charge air manifold   AR09.41-P-1310GZB
5 Remove primary catalytic converter   AR49.10-P-7100GZB
6 Remove cylinder head covers   AR01.20-P-5014GZB 
7 Remove oil filter housing   AR18.20-P-3471GZB
8 Remove high-pressure pump   AR07.02-P-1020GZB
9 Remove camshaft sprockets IMPORTANTInstallation:  Check basic position of camshaft, see: ↓ AR05.20-P-6040OM
Check basic position of camshafts AR05.20-P-6010OM
10 Remove camshafts   AR05.20-P-6992OM
11 Remove heat shield (3) above exhaust manifolds    
12 Remove slide rail pins (7) IMPORTANT In the case of an existing slide rail bolt (7) on the right next to the oil filter housing in the engine block this should be removed analog to the slide rail bolt (7) in the cylinder head. This ensures that the left slide rail is movable. AR01.30-P-5800-04PI 
SPECIAL TOOL Impact extractor Fig 3
SPECIAL TOOL Threaded stud Figure
SPECIAL TOOL Extractor Figure
13 Slacken cylinder head bolts in stages and remove NOTES Slacken cylinder head bolts in the reverse sequence to the tightening procedure when the engine has cooled down to prevent warping of cylinder head, see: ↓  
Tightening procedure for cylinder head bolts
NOTESInstallation:  Observe tightening procedure and tightening specifications for cylinder head bolts to prevent warping of cylinder head, see. ↓		 AR01.30-P-5800-01PI 
Tightening procedure for cylinder head bolts
IMPORTANTInstallation:  Oil cylinder head bolts at thread and bolt head contact surface.		 AR01.30-P-5800-01PI 
TORQUE SPECIFICATION Bolt, cylinder head to crankcase *BA01.30-P-1001-01S 
TORQUE SPECIFICATION Bolt, cylinder head to crankcase M12 *BA01.30-P-1002-01S 
14 Remove right cylinder head (1) and left cylinder head (2)    
15 Detach exhaust manifold IMPORTANT Only when replacing cylinder heads.  
TORQUE SPECIFICATION Exhaust manifold to cylinder head (stud bolt) *BA01.30-P-1003-01S 
CLEAN Clean     
16 Clean threaded holes and sealing surfaces IMPORTANT Clean threaded holes as well as sealing surfaces on crankcase, right cylinder head (1) and left cylinder head (2).  
INSPECT Checking     
17 Check cylinder head bolts and replace if necessary   AR01.30-P-5800-03PI 
Cylinder head bolt *BE01.30-P-1001-04A 
18 Install in the reverse order    
19 Read out fault memory and erase IMPORTANT Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.  
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04A
DANGER 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
20 Check for leaks with engine running    
21 Bleed cooling system IMPORTANT Warm up engine to normal operating temperature and fully open heater temperature control (position "hot"). AR20.00-P-1142GZB
CYLINDER HEAD/CYLINDER HEAD BOLTS

Number Designation Engine 642
BE01.30-P-1001-04A Cylinder head bolt Thread diameter M 12
Length (L) when new mm 205
Max. length (L) mm 207
See picture -
CYLINDER HEAD

Number Designation Engine 642
BA01.30-P-1001-01S Bolt, cylinder head to crankcase M8x35 Nm 20
BA01.30-P-1002-01S Bolt, cylinder head to crankcase M12 Stage 1 Nm 10
Stage 2 Nm 60
Stage 3 ∠° 90
Stage 4 ∠° 90
Stage 5 ∠° 90
BA01.30-P-1003-01S Exhaust manifold to cylinder head (stud bolt) Nm 20
Fig 2: Identifying Threaded Stud (116 589 01 34 00)
G07252920Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Impact Extractor (116 589 20 33 00)
G07252921Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Puller (605 589 00 33 00)
G07252922Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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