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Home >> Mercedes Benz >> 2009 >> CL600 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Complete Engine -- Cl600 (216.376) >> Testing & Repair >> Remove/install cylinder head - AR01.30-P-5800M

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

ENGINES 275 in MODELS 215, 216, 220, 221, 230 

Fig 1: Identifying Cylinder Head Components (1 Of 3)
G07541564Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Cylinder Head Components (2 Of 3)
G07541565Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Cylinder Head Components (3 Of 3)
G07541566Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

22.11.05 Remove engine 275.951/981 with front axle carrier added Step 1.2
REMOVINGINSTALLING Remove/install     
1.1 Remove engine Model 215, 220 except 220 with code (979) Special protection version, code (Z04) Light armoring or code (Z07) Highest protection
Model 220 with special protection version, code (979), Light armoring code (Z04) or highest protection code (Z07)		 AR01.10-P-2400MC
1.2 Remove engine with front axle carrier Model 230 without code (P99) Special model "AMG Black Series" AR01.10-P-2500RC
    Model 230 with code (P99) Special model "AMG Black Series" AR01.10-P-2500RBS
    Model 216, 221 AR01.10-P-2500SZ 
2 Mount engine onto assembly stand Model 215, 220  
3 Remove right air filter housing Model 215, 216, 220, 221, 230 without code (P99) Special Model "AMG Black Series" AR09.10-P-1150LA
4 Remove charge air cooler   AR09.41-P-6817HH
5 Remove engine charge air channel upstream of charge air cooler   AR09.41-P-8623H
6 Remove coolant thermostat housing   AR20.10-P-2710M
7 Remove ignition coil module   AR15.12-P-1100LA
8 Remove cylinder head covers   AR01.20-P-5014H 
9 Remove left front cover at cylinder head   AR01.30-P-5700ML 
10 Remove right front cover at cylinder head   AR01.30-P-5700MR 
11 Remove charge air manifold   AR09.41-P-1310HH
12 Position piston of cylinder a 1 to 30° crank angle after ignition TDC NOTES The engine must not be turned back, otherwise the timing chain can skip and this can result in engine damage!
IMPORTANT Rotate engine at crankshaft in direction of engine rotation until marking for a 30° crank angle on the belt pulley/vibration damper (1) coincides with marking on the timing case cover (arrow). The camshaft bearing cap marker (A) must be aligned with camshaft (B) marker.		  
13 Remove chain tensioner Model 215, 220 AR05.10-P-7800M
    Model 216, 221 AR05.10-P-7800SZ
    Model 230 AR05.10-P-7800R
14 Remove circlip (4) on camshaft sprocket for left cylinder bank (5) and remove centrifuge (6) IMPORTANTInstallation:  Replace O-ring (7).  
15 Remove camshaft sprocket for left cylinder bank (5) and camshaft sprocket for right cylinder bank (8) IMPORTANT Mark camshaft sprocket for left cylinder bank (5), camshaft sprocket for right cylinder bank (8) and timing chain relative to each other.  
    IMPORTANT Turn camshafts (3) in such a way that retaining devices (9) can be mounted free of tension on cylinder heads (10, 11).  
    TORQUE SPECIFICATION *BA05.20-P-1001-02I 
    SPECIAL TOOL *104589010100
    SPECIAL TOOL Retaining device for left camshaft *285589004000
    SPECIAL TOOL Retaining device for right camshaft *137589014000
16 Remove turbocharger (13) support (12) TORQUE SPECIFICATION *BA09.40-P-1009-01H 
    TORQUE SPECIFICATION *BA09.40-P-1010-01H 
17 Remove coolant feed line (14) from crankcase to turbocharger (13) TORQUE SPECIFICATION *BA09.40-P-1005-01H 
    TORQUE SPECIFICATION *BA09.40-P-1007-01H 
18 Remove oil return flow line (15) at turbocharger (13) TORQUE SPECIFICATION *BA09.40-P-1004-01H 
    TORQUE SPECIFICATION *BA09.40-P-1006-01H 
19 Detach pneumatic line (26) INSPECT Check condition of pneumatic line (26) and hose clamp, replace if required.  
20 Remove oil lines (27) from cylinder heads (10, 11) TORQUE SPECIFICATION *BA09.40-P-1015-01H 
21 Remove coolant lines (25) from cylinder heads (10, 11) TORQUE SPECIFICATION *BA09.40-P-1001-01H 
22 Remove bolts (22) on power steering pump bracket from left cylinder head (10) TORQUE SPECIFICATION *BA01.30-P-1008-01G 
23
 
 		 Remove slide rail bolts (16) and slide rail (17) from right cylinder head (11) IMPORTANT Slide rail pins (16) have different length.  
 
 		 SPECIAL TOOL *116589013400
SPECIAL TOOL *116589203300
24 Remove bolts (18) on left cylinder head (10) TORQUE SPECIFICATION *BA01.40-P-1002-01C 
25 Remove bolts (19) on right cylinder head (11) TORQUE SPECIFICATION *BA01.40-P-1002-01C 
26 Loosen and unscrew cylinder head bolts (20, 21) in stages IMPORTANT Loosen cylinder head bolts (20, 21) according to loosening pattern on cooled off engine. AR01.30-P-5800-09M 
    IMPORTANTInstallation:  Observe different bolt lengths!  
    IMPORTANTInstallation:  Lubricate cylinder head bolts (20, 21) at threads and bolt head contact surfaces.  
    TORQUE SPECIFICATION *BA01.30-P-1004-01G 
    SPECIAL TOOL *000589031000
    SPECIAL TOOL *000589041000
27 Take off cylinder heads (10, 11) IMPORTANTInstallation:  Replace cylinder head gaskets (23, 24). Observe tightening procedure and tightening specifications for cylinder head bolts (20, 21):
Tightening procedure		 AR01.30-P-5800-07M 
28 Inspect cylinder head bolts (20, 21)   AR01.30-P-5800-03M 
CLEAN Clean     
29 Clean threaded holes as well as sealing surfaces on cylinder heads (10, 11) and cylinder crankcase NOTES Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces. AR01.00-P-0050-01A 
    Loctite 7200 *BR00.45-Z-1038-04A 
    Loctite 7063 cleaning spray (150 ml) *BR00.45-Z-1046-04A 
INSPECT Checking     
30 Check sealing surfaces for cracks, shrink holes and flatness IMPORTANT The sealing surfaces between crankcase and the cylinder heads (10, 11) are provided with a 0.8 mm thick silicone layer during standard production assembly. Silicone sealant is applied in the gasket area when carrying out repairs only if shrink holes are present.
IMPORTANT The sealant must be worked on within 10 minutes.
IMPORTANT Pay attention to dowel sleeves for locating the cylinder heads (10, 11).		  
    SPECIAL TOOL *112589002500
    Loctite 5970 sealant *BR00.45-Z-1013-01A 
31 Install in the reverse order    
CYLINDER HEAD

Number Designation     Engine 275
BA01.30-P-1004-01G Internal Torx bolt, cylinder head to crankcase Stage 1 Nm 40
    Stage 2 °∠ 90
    Stage 3 °∠ 90
BA01.30-P-1008-01G Bolt, power steering pump bracket to cylinder head   Nm 20
CRANKCASE, TIMING CASE COVER, END COVER

Number Designation   Engine 275, 285
BA01.40-P-1002-01C Bolt, cylinder head to timing case cover Nm 8
CAMSHAFT

Number Designation       Engine 275, 285
BA05.20-P-1001-02I Camshaft sprocket bolt M8x16 Stage 1 Nm 20
      Stage 2 ∠° 90
TURBOCHARGER

Number Designation   Engine 275
BA09.40-P-1001-01H Coolant line to cylinder head Nm 9
BA09.40-P-1004-01H Bolt, oil return flow line to turbocharger Nm 8
BA09.40-P-1005-01H Bolt connecting coolant feed line to turbocharger Nm 8
BA09.40-P-1006-01H Bolt, oil return flow line to crankcase Nm 8
BA09.40-P-1007-01H Banjo bolt, coolant feed line to crankcase Nm 25
BA09.40-P-1009-01H Bolt, support to turbocharger Nm 30
BA09.40-P-1010-01H Bolt, turbocharger support to crankcase Nm 20
BA09.40-P-1015-01H Bolt, oil feed line to cylinder head Nm 8
Fig 4: Identifying Open-End Wrench, Double (104 589 01 01 00)
G07541567Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Squeeze Gun (112 589 00 25 00)
G07541568Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Impact Extractor (116 589 20 33 00)
G07541569Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Threaded Stud (116 589 01 34 00)
G07541570Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Screwdriver Insert (000 589 03 10 00)
G07541571Courtesy of MERCEDES-BENZ USA
Fig 9: Identifying Screwdriver Insert (000 589 04 10 00)
G07541572Courtesy of MERCEDES-BENZ USA
Fig 10: Identifying Holding Device (285 589 00 40 00)
G07541573Courtesy of MERCEDES-BENZ USA
Fig 11: Identifying Holding Device (137 589 01 40 00)
G07541574Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
BR00.45-Z-1038-04A Loctite 7200
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
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