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

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ENGINE 271.940 in MODEL 203.042 /242 /742, 209.342 /442

ENGINE 271.946 in MODEL 203.046 /246 /746

ENGINE 271.948 in MODEL 203.040 /240 /740

ENGINE 271.942 in MODELS 203.043 /243 /743, 209.343

ENGINE 271.921 in MODEL 203.730

ENGINE 271.955 in MODEL 209.341 /441

Shown on model 209 with engine 271

Fig 1: Identifying Cylinder Head Remove/Install Components - Shown On Model 209 With Engine 271 (1 Of 3)

Fig 2: Identifying Cylinder Head Remove/Install Components - Shown On Model 209 With Engine 271 (2 Of 3)

Fig 3: Identifying Cylinder Head Remove/Install Components - Shown On Model 209 With Engine 271 (3 Of 3)

MODIFICATION NOTES

25.9.06

Nut, exhaust manifold to cylinder head

Engine 271

*BA14.10-P-1001-01E

	Remove/install
1	Open engine hood	Model 203	AR88.40-P-1000P
		Model 209	AR88.40-P-1000Q
	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 leadacid 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
2	Disconnect ground line from battery	Model 203	AR54.10-P-0003P
		Model 209	AR54.10-P-0003Q
	Notes on battery		AH54.10-P-0001-01A
	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
3	Drain the coolant at the radiator and at the crankcase		AR20.00-P-1142PR
	Notes on coolant		AH20.00-N-2080-01A
4	Remove air filter housing		AR09.10-P-1150Q
5	Detach cover at cylinder head (8)	Grasp cover at cylinder head (8) with both hands and pry off. Check gasket, replace if necessary.
6	Separate engine-side engine wiring harness	To do this unplug plugs at the following components: left intake camshaft Hall sensor (B6/4), right exhaust camshaft Hall sensor (B6/7), coolant temperature sensor (B11/4), air pump switchover valve (Y32), camshaft exhaust solenoid (Y49/3), camshaft intake solenoid (Y49/1)
7	Remove ignition coils		AR15.12-P-2003T
8	Remove cylinder head cover (120)		AR01.20-P-5014QK
9	Remove front cover at cylinder head (8)		AR01.30-P-5700QK
10	Move camshafts (6) into basic position		AR05.20-P-6010QK
11	Remove chain tensioner		AR05.10-P-7800QK
12	Remove upper camshaft housing (5)		AR05.20-P-6995QK
13	Remove camshafts (6)	Detach timing chain and secure for this step.	AR05.20-P-6992QK
14	Remove sliding rail bolts (2) on left slide rail		AR01.30-P-5800-04GS
		Threaded stud	Figure
		Impact extractor	Figure
15	Remove intake manifold (1)	Engine 271.921 /940 /946 /948 /955	AR09.20-P-1310QK
		Engine 271.942	AR09.20-P-1310Q
16	Dismount shield (3) at camshaft bearing housing		*BA05.20-P-1004-03A
17	Slacken exhaust manifold (4) from cylinder head	Installation: Replace gasket, so that gasket related leakage can be precluded.
		Unscrew upper nuts and lift out exhaust manifold (4).	AR14.10-P-4095QK
			*BA14.10-P-1001-01E
18	Slacken cylinder head bolts in the reverse order of the tightening procedure	Cylinder head tightening procedure	AR01.30-P-5800-07QA
		Installation: Check cylinder head bolts and replace if necessary.	AR01.30-P-5800-03HA
		Cylinder head bolt	*BE01.30-P-1001-04B
			*BA01.30-P-1002-01J
19	Remove cylinder head (8)	Installation: replace cylinder head gasket (9). When fitting on the cylinder head (8) pay attention to the slide rail.
	Clean
20	Clean sealing surfaces at the cylinder head (8) and at the crankcase	Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.
		LU cleaner	*BR00.45-Z-1028-04A
21	Check separating surfaces for cylinder head (8) and crankcase for cracks and unevenness	The cylinder head (8) and the crankcase must not be post-worked (face grind), because the production tolerances must not be below the limit.
22	Blow out the tapped holes of the cylinder head bolts in crankcase with compressed air and clean from oil and water
23	Install in the reverse order
	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
24	Check for leaks with engine running
25	Inspect cooling system for leaks		AR20.00-P-1010P
26	Perform basic programming	Model 203	AR00.19-P-0200P
		Model 209	AR00.19-P-0200Q

CYLINDER HEAD/CYLINDER HEAD BOLTS

Number	Designation			Engine 271
BE01.30-P-1001-04B	Cylinder head bolt	Thread diameter	M	10x1.5
		Length (L) when new	mm	165
		Length (L)	mm	167.5
		See picture		-

CYLINDER HEAD

Number	Designation				Engine 271
BA01.30-P-1002-01J	Bolt, cylinder head	M10	Stage 1	Nm	45
			Stage 2	∠ °	90
			Stage 3	∠ °	90
			See picture		-

CAMSHAFT BEARING HOUSING

Number	Designation			Engine 271
BA05.20-P-1004-03A	Shield to camshaft bearing housing	M6	Nm	8

EXHAUST MANIFOLD

Number	Designation		Engine 271
BA14.10-P-1001-01E	Nut, exhaust manifold to cylinder head	Nm	21

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

Fig 5: Identifying Impact Extractor (116 589 20 33 00)

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