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

ENGINE 275 in MODEL 215, 216, 220, 221, 230 

ENGINE 285 in MODEL 240 

Fig 1: Identifying Cylinder Head Remove/Install Components (1 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Cylinder Head Remove/Install Components (2 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Cylinder Head Remove/Install Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

	Remove/install
1.1	Remove engine	ENGINE 275 in MODEL 215, 220 ENGINE 285 in MODEL 240
		ENGINE 275 in MODEL 215, 220 with CODE 487 (Active Body Control (ABC))	AR01.10-P-2400MC
		ENGINE 285 in MODEL 240	AR01.10-P-2400H
1.2	Remove engine with front axle carrier	ENGINE 275 in MODEL 216, 221, 230
		ENGINE 275 in MODEL 230 without CODE P99 (Special model "AMG Black Series")	AR01.10-P-2500RC
		ENGINE 275 in MODEL 230 with CODE P99 (Special model "AMG Black Series")	AR01.10-P-2500RBS
		ENGINE 275 in MODEL 216, 221	AR01.10-P-2500SZ
2	Secure engine to assembly stand
		ENGINE 275 in MODEL 215, 220 ENGINE 285 in MODEL 240	WS01.00-N-3028B
3	Remove right air filter housing	ENGINE 285 in MODEL 240	AR09.10-P-1150H
		ENGINE 275 in MODEL 215, 216, 220, 221 ENGINE 275 in MODEL 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 duct upstream of charge air cooler		AR09.41-P-8623H
6	Remove coolant thermostat housing		AR20.10-P-2710M
7	Remove ignition coil	ENGINE 285 in MODEL 240	AR15.12-P-1100H
		ENGINE 275 in MODEL 215, 216, 220, 221, 230	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 distributor		AR09.41-P-1310HH
12	Position piston of cylinder a 1 to 30° crank angle after ignition TDC	The engine must not be turned back against the direction of engine rotation. The timing chain can skip otherwise and engine damage can occur. 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 marking (B) of the camshaft (3) is slightly offset to the left at a 30° CKA after ignition TDC or the inserted holding device (9) to the right cylinder head (11) and holding device (9) at the left cylinder head (10) to the marking (A) of the camshaft bearing cap (2).
		Retaining device	Fig 10
		Retainer device	Fig 8
13	Remove chain tensioner	ENGINE 275 in MODEL 215, 220 ENGINE 285 in MODEL 240	AR05.10-P-7800M
		ENGINE 275 in MODEL 216, 221	AR05.10-P-7800SZ
		ENGINE 275 in MODEL 230	AR05.10-P-7800R
14	Remove retaining ring (4) on camshaft sprocket for left cylinder bank (5) and remove centrifuge (6)	Replace O-ring (7).
15	Mark camshaft sprocket for left cylinder bank (5), camshaft sprocket for right cylinder bank (8) and timing chain relative to each other.
16	Remove camshaft sprocket for left cylinder bank (5) and camshaft sprocket for right cylinder bank (8)	Turn the camshafts (3) so that open-end wrench, double so that the holding device (9) is mounted on the left cylinder head (10) and the holding device (9) on the right cylinder head (11) unstressed.
		Camshaft sprocket bolt	*BA05.20-P-1001-02I
		Double open end wrench	Fig 6
		Retaining device	Fig 10
		Retainer device	Fig 8
17	Remove ATL (13) support (12)	Bolt, support brace to turbocharger	*BA09.40-P-1009-01H
		Bolt, turbocharger support brace to crankcase	*BA09.40-P-1010-01H
18	Remove coolant feed line (14) from crankcase to ATL (13)	Bolt, coolant feed line to turbocharger	*BA09.40-P-1005-01H
		Banjo bolt, coolant feed line to crankcase	*BA09.40-P-1007-01H
19	Detach oil return line (15) at ATL (13)	Bolt, oil return flow line to turbocharger	*BA09.40-P-1004-01H
		Bolt, oil return line to crankcase	*BA09.40-P-1006-01H
20	Detach air line (26)
21	Check air line (26) and hose clamp	Check for damage and replace if necessary.
22	Detach oil lines (27) from cylinder heads (10, 11)	Bolt, oil line to cylinder head	*BA09.40-P-1015-01H
23	Detach coolant lines (25) from cylinder heads (10, 11)	Coolant line to cylinder head	*BA09.40-P-1001-01H
24	Remove screw/bolts (22) on power steering pump bracket from left cylinder head (10)	Bolt, power steering pump bracket to cylinder head	*BA01.30-P-1008-01G
25	Remove slide rail bolts (16) and slide rail (17) from right cylinder head (11)	Slide rail pins (16) have different length.
		Threaded bolt	Figure
		Impact extractor	Figure
26	Remove screw/bolts (18) on left cylinder head (10)	Screw/bolt, cylinder head to timing case cover	*BA01.40-P-1002-01C
27	Remove screw/bolts (19) on right cylinder head (11)	Screw/bolt, cylinder head to timing case cover	*BA01.40-P-1002-01C
28	Loosen and unscrew cylinder head bolts (20, 21) in stages according to loosening procedure	Slackening diagram for cylinder head bolts	AR01.30-P-5800-09M
		Tightening specifications for cylinder head bolts Only loosen cylinder head bolts (20, 21) when engine has cooled off. Pay attention to tightening specifications for cylinder head bolts (20, 21). Observe the different screw lengths of the cylinder head bolts (20, 21). Lubricate cylinder head bolts (20, 21) at threads and bolt head contact surfaces.	AR01.30-P-5800-07M
		Internal Torx bolt, cylinder head to crankcase	*BA01.30-P-1004-01G
		Screwdriver bit	Fig 9
		Screwdriver insert	Fig 5
29	Take off cylinder heads (10, 11)	Replace cylinder head gaskets (23, 24). Pay attention to pilot bushing for fixing the cylinder heads (10, 11).
	Clean
30	Clean threaded holes as well as sealing surfaces on cylinder heads (10, 11) and crankcase		AR01.00-P-0050-01A
		Do not use any sharp-edged tools or abrasive paper. The sealing surfaces can be damaged otherwise.
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
	Check
31	Check cylinder head bolts (20, 21)		AR01.30-P-5800-03M
		Cylinder head bolt	*BE01.30-P-1001-04B
32	Check sealing surfaces on cylinder heads (10, 11) for cracks, shrink hose inclusions and unevenneses, if necessary replace the timing case cover, cylinder heads (10, 11) or crankcase	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. For repair installation the sealant is only applied for shrink hose inclusions in the sealing area. The sealant must be processed within 10 minutes.
		Loctite 5970 sealant	*BR00.45-Z-1013-01A
		Application gun	Figure
33	Install in the reverse order

Fig 4: Identifying Application Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Screwdriver Insert (000 589 04 10 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Double Open End Wrench (104 589 01 01 00)

Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Threaded Bolt (116 589 01 34 00)

Courtesy of MERCEDES-BENZ USA

Fig 8: Identifying Retainer Device (137 589 01 40 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 10: Identifying Retaining Device (285 589 00 40 00)

Courtesy of MERCEDES-BENZ USA

Fig 11: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ USA