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

ENGINES 272.946/965/974/975 in MODEL 221 Left cylinder head

ENGINES 273.922/924/961/968 in MODEL 221 Left cylinder head

ENGINES 273.961/968 in MODEL 216 Left cylinder head

Fig 1: Identifying Cylinder Head Remove/Install Components

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Cylinder Head Remove/Install Components - Shown On Model 221.071

Courtesy of MERCEDES-BENZ USA

Shown on model 221.071 with code (487) Active Body Control (ABC)

MODIFICATION NOTES

27.2.12

Reference to modified version of poly-V belt, added

Operation step 9

BT13.20-P-1000-01SXH

	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 death when touching components on vehicles with high-voltage on-board electrical system	Do not touch components and open lines of the high-voltage on-board electrical system. Persons who are carriers of electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems.	AS54.00-Z-0001-01A
1	Perform enable for the high-voltage on-board electrical system	Model 221.095/195 After completing the work, attach initial startup event log together with the disconnection log to the vehicle file.	AR54.10-P-1150SXH
	Note on the high-voltage on-board electrical system		AH54.00-P-0010-01A
2	Switch off ignition
3	Detach ground line(s) from battery/batteries	Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery.	AR54.10-P-0003SX
4	Remove bottom engine compartment paneling	Only install bottom engine compartment paneling after engine test run.	AR61.20-P-1105SX
5	Drain coolant at radiator and at cylinder crankcase (1)		AR20.00-P-1142SX
	Notes on coolant		AH20.00-N-2080-01A
6	Detach left catalytic converter (2) from exhaust manifold (4)		*BA49.10-P-1001-01Z
7	Remove air filter housing		AR09.10-P-1150SX
8	Remove ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008SX
9	Remove poly-V-belt tensioning device	Except model 221.095/195 with two-belt drive	AR13.20-P-0001SX
	Poly-V belt version changed	Model 221.095/195	BT13.20-P-1000-01SXH
10	Remove power steering expansion reservoir	Vehicles with AIRmatic except model 221.095/195	AR46.25-P-1000SX
11	Remove oil filter housing (5) with oil-water heat exchanger		AR18.20-P-3471SX
12	Detach electric refrigerant compressor and place to one side with lines attached	Model 221.095/195 Secure electric refrigerant compressor against falling down.	AR83.55-P-5300SXH
13	Remove front cover (6) at left cylinder head (7)	After installation of front cover (6) check that position of camshafts is at a 55° crank angle before top dead center (TDC): ↓	AR01.30-P-5700SX
		Check basic position of camshafts.	AR05.20-P-6010SX
			Figure
14	Remove ignition coils at right cylinder head		AR15.12-P-2003SX
15	Remove oil separator (8)		AR01.20-P-9750SX
16	Remove resonance intake manifold (10)		AR09.20-P-1961SX
17	Remove left cylinder head cover (9)		AR01.20-P-5014SX
18	Rotate engine at crankshaft center bolt in direction of rotation of the engine to a 40° crankshaft angle after top dead center (TDC)	Pay attention to position of camshafts.	AR05.20-P-6010-01VB
18			Figure
19	Remove chain tensioner	Install new chain tensioner. The previously installed chain tensioner must not be reinstalled because during removal, its pressure pin is pressed into the end position. The thrust pin latch prevents this return stroke. This would overstretch the timing chain on reinstalling.	AR05.10-P-7800SX
20	Remove both camshaft adjuster (11) at left cylinder head (7)	Intake camshaft	AR05.20-P-7201SX
20		Exhaust camshaft	AR05.20-P-7201SY
21	Remove air shutoff valve (12) at left cylinder head (7)		AR14.30-P-7200SX
22	Remove intermediate flange (12a) of air shutoff valve (12)		*BA14.30-P-1004-02A
23	Pull out slide rail pins (14) from left cylinder head (7)	Apply sealant to slide rail pins (14) before inserting them.	AR01.30-P-5800-04V
			Figure
			Figure
			Figure
		Loctite 5970 sealant	*BR00.45-Z-1013-01A
24	Detach coolant hose (13) from heater valve
25	Disconnect electrical connector at coolant temperature sensor (B11/4)
26	Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them	To avoid stresses in cylinder head (7), the cylinder head bolts must be loosened only when the engine has cooled off. Tightening procedure:
		Engine 272	AR01.30-P-5800-07VA
		Engine 273	AR01.30-P-5800-07SX
			*BA01.30-P-1003-01O
			*BA01.30-P-1016-01O
27	Remove LH cylinder head (7) from cylinder crankcase (1)	Place new cylinder head gasket (15) on crankcase (1). Pay attention to the fitting sleeves for fixing the cylinder head (7).
	Notes on application of sealant to cylinder head gasket (15)		AH01.30-P-1000-04RX
	Clean
28	Clean sealing surfaces at left cylinder head (7), timing case cover and cylinder crankcase (1)	Do not use any sharp-edged tools or abrasive paper. The sealing surfaces will be damaged otherwise.	AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
29	Blow out the tapped holes for cylinder head bolts in crankcase (1) with compressed air, and clean off the engine oil and the coolant
	Checking
30	Check cylinder head bolts and replace if required		AR01.30-P-5800-03VA
30	Check cylinder head bolts and replace if required	Cylinder head bolt	*BE01.30-P-1001-04B
31	Check sealing surfaces at left cylinder head (7), timing case cover and cylinder crankcase (1) for cracks and unevenness	Cylinder head (7) and cylinder crankcase (1) must not be reworked (surface grinding). Otherwise the permissible production tolerances will be exceeded. In the event of any complaint, replace cylinder head (7), timing case cover or cylinder crankcase (1). Possible warping of the cylinder head (7) in the longitudinal or transverse direction is compensated for again when reassembled by tightening the cylinder head bolts.
32	Install in the reverse order
33	Change engine oil and oil filter element
	Engine - oil and filter change		AP18.00-P-0101SX
	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
34	Carry out an engine test run, and check engine and fuel system for leaks

CYLINDER HEAD/CYLINDER HEAD BOLTS

Number	Designation			Engine 272	Engine 273
BE01.30-P-1001-04B	Cylinder head bolt	Thread diameter	M	11	11
		Length (L) when new	mm	170	170
		Length (L)	mm	172	172
		-		-	-

EXHAUST SYSTEM

Number	Designation		Engine 272 in model 221	Engine 273 in model 221	Engine 273 in model 216
BA49.10-P-1001-01Z	Bolt, catalytic converter to exhaust manifold	Nm	25	25	25

AIR SHUTOFF VALVE

Number	Designation		Engine 272	Engine 273
BA14.30-P-1004-02A	Bolt, left air shutoff valve intermediate flange to cylinder head	Nm	14	14

CYLINDER HEAD

Number	Designation				Engine 272	Engine 273
BA01.30-P-1003-01O	Cylinder head bolt on timing case	M8		Nm	20	20
BA01.30-P-1016-01O	Bolt, cylinder head to crankcase	M11	Stage 1	Nm	20	20
			Stage 2	Nm	50	50
			Stage 3	∠°	90	90
			Stage 4	∠°	90	90

Fig 3: Identifying Wrench Socket (001 589 65 09 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Threaded Stud (116 589 01 34 00)

Courtesy 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	Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10