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

ENGINES 156 in MODEL 216, 221

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

6.8.09

Value changed: Bolt, camshaft adjuster on camshaft, 1st stage

*BA05.20-P-1001-02J

	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		AH00.00-N-0001-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
1	Turn key in ignition lock to position "0"
2	Open engine hood and raise to vertical position
	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	Detach ground line from battery		AR54.10-P-0003SX
	Notes on battery		AH54.10-P-0001-01A
4	Raise vehicle with vehicle lift		AR00.60-P-1000SX
5	Remove bottom engine compartment paneling	Only install bottom engine compartment paneling after engine test run.	AR61.20-P-1105SX
6	Drain coolant		AR20.00-P-1142SMG
7	Remove catalytic converter from exhaust manifold	According to which cylinder head (7) should be removed.
8	Remove air filter housing	Lift front engine cover vertically upwards otherwise the retaining lugs can break off.	AR09.10-P-1150SMG
9	Remove spark plugs	Only if it is not possible to crank engine due to high compression.	AR15.12-P-1010SMG
10	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.
11	Remove electric fan		AR20.40-P-5000SMG
12	Remove intake manifold (1)		AR09.20-P-1961SMG
13	Remove poly-V belt (2)		AR13.22-P-1202SMG
14	Remove alternator (G2)		AR15.40-P-5032SMG
15	Remove chain tensioner		AR05.10-P-7800SMG
	Left-hand side
16	Remove left cylinder head cover (4)		AR01.20-P-5014SMG
17	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 Lock camshaft adjuster at rear using a bolt. Use retaining device (01) and associated straightedge to loosen camshaft adjuster. 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
			Fig 3
18	Remove camshaft drive gear (8) at left cylinder head (7)		AR05.20-P-7201-07AMG
			*BA05.20-P-1003-02J
			Figure
			Fig 4
19	Remove camshafts		AR05.20-P-6992AMG
20	Remove left combination valve (9)	Also remove air line (10) on cylinder head (7). Insert air line (10) before assembling the cylinder head (7). Later assembly is only possible if the power steering pump is removed. Replace gasket.	AR14.30-P-7255SMG
21	Remove oil filter housing (11)		AR18.20-P-3471SMG
21	Remove oil filter housing (11)		Fig 7
22	Pull out slide rail pins from left cylinder head (7)		AR01.30-P-5800-04AMG
			Figure
			Figure
23	Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them	Cylinder head bolts must be replaced. 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
24	Remove cylinder head (7) from crankcase (12)	Place new cylinder head gasket (12) on crankcase. Pay attention to fitted sleeves for fixing cylinder head (7).
	Right-hand side
25	Remove right cylinder head cover (13)		AR01.20-P-5014SMG
26	Disconnect connector from coolant temperature sensor
27	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 Lock camshaft adjuster at rear using a bolt. Use retaining device (01) and associated straightedge to loosen camshaft adjuster. 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
			Fig 5
			Fig 3
28	Remove camshaft drive gear (8) at right cylinder head (7)		AR05.20-P-7201-07AMG
			*BA05.20-P-1003-02J
			Figure
			Fig 4
29	Remove camshafts		AR05.20-P-6992AMG
30	Remove right combination valve (14) for air pump	Only remove air line (15) on cylinder head (7). Install new gasket	AR14.30-P-7255SMG
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
			Figure
			Figure
33	Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them	Cylinder head bolts must be replaced. 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)	Place new cylinder head gasket (12) on crankcase. Pay attention to fitted sleeves for fixing cylinder head (7).
	Clean
35	Clean sealing surfaces at cylinder head (7) and at cylinder 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.	AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
	Checking
36	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.
37	Install in the reverse order
38	Change engine oil and oil filter element
	Engine - oil and filter change		AP18.00-P-0101TMG
39	Perform basic programming
	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
40	Carry out an engine test run, and check engine and fuel system for leaks
41	Inspecting cooling system for leaks		AR20.00-P-1010SX
42	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

CAMSHAFT, CAMSHAFT ADJUSTMENT

Number	Designation				Engine 156
BA05.20-P-1001-02J	Bolt, camshaft adjuster to camshaft	M12	Stage 1	Nm	45
BA05.20-P-1001-02J	Bolt, camshaft adjuster to camshaft	M12	Stage 2	∠°	90
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
			Stage 5	∠°	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