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

ENGINES 642 in MODEL 221 

Fig 1: Identifying Cylinder Head Remove/Install Components

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

23.10.08	Remove/install high-pressure pump-added	Operation step 7
23.10.08	Check basic position of camshaft - added	Step 8

	Remove/install
	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
	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 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 goggles. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on coolant		AH20.00-N-2080-01A
	Notes on battery		AH54.10-P-0001-01A
	Notes on assigning the cylinder head gaskets		AH01.30-P-1000-06TQ
1	Disconnect battery ground line		AR54.10-P-0003SX
2	Drain and collect coolant from radiator		AR20.00-P-1142SXI
		Cooling system	*BF20.00-P-1001-02W
3	Remove charge air manifold		AR09.41-P-1310SXI
4	Remove primary catalytic converter	To remove primary catalytic converter see: ↓ With code (474) Particulate filter
		Remove/install components for exhaust system	AR49.10-P-7100SXI
5	Remove cylinder head covers		AR01.20-P-5014SXI
6	Remove oil filter housing		AR18.20-P-3471SXI
7	Remove high-pressure pump		AR07.02-P-1020SXI
8	Remove camshaft sprockets	Check basic position of camshaft, see: ↓	AR05.20-P-6040OM
		Check basic position of camshafts	AR05.20-P-6010OM
9	Remove camshafts		AR05.20-P-6992SXI
10	Remove heat shield (3) above exhaust manifolds
11	Remove slide rail pins (7)	In the case of an existing slide rail bolt (7) on the right next to the oil filter housing in the engine block this should be removed analog to the slide rail bolt (7) in the cylinder head. This ensures that the left slide rail is movable.	AR01.30-P-5800-04TI
		Impact extractor	Figure
		Threaded stud	Figure
		Extractor	Fig 4
12	Slacken cylinder head bolts in stages and remove	Slacken cylinder head bolts in the reverse sequence to the tightening procedure when the engine has cooled down to prevent warping of cylinder head, see: ↓
		Tightening procedure for cylinder head bolts Oil cylinder head bolts at thread and bolt head contact surface.	AR01.30-P-5800-01SXI
		Bolt, cylinder head to crankcase	*BA01.30-P-1001-01S
		Bolt, cylinder head to crankcase M12	*BA01.30-P-1002-01S
13	Remove right cylinder head (1) and left cylinder head (2)
14	Detach exhaust manifold	Only when replacing cylinder heads.
		Exhaust manifold to cylinder head (stud bolt)	*BA01.30-P-1003-01S
	Clean
15	Clean threaded holes and sealing surfaces	Clean threaded holes as well as sealing surfaces on crankcase, right cylinder head (1) and left cylinder head (2).
	Checking
16	Check cylinder head bolts and replace if necessary		AR01.30-P-5800-03TQ
		Cylinder head bolt	*BE01.30-P-1001-04A
17	Install in the reverse order
18	Read out fault memory and erase	Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
19	Check for leaks with engine running
20	Bleed cooling system	Warm up engine to normal operating temperature and fully open heater temperature control (position "hot").	AR20.00-P-1142-06SXI

CYLINDER HEAD/CYLINDER HEAD BOLTS

Number	Designation			Engine 642
BE01.30-P-1001-04A	Cylinder head bolt	Thread diameter	M	12
		Length (L) when new	mm	205
		Max. length (L)	mm	207
		-		-

CYLINDER HEAD

Number	Designation			Engine 642
BA01.30-P-1001-01S	Bolt, cylinder head to crankcase	M8x35	Nm	20
BA01.30-P-1002-01S	Bolt, cylinder head to crankcase M12	Stage 1	Nm	10
		Stage 2	Nm	60
		Stage 3	∠°	90
		Stage 4	∠°	90
		Stage 5	∠°	90
BA01.30-P-1003-01S	Exhaust manifold to cylinder head (stud bolt)		Nm	20

COOLING SYSTEM

Number	Designation			Engine 642 in model 203, 209, 211, 219, 221
BF20.00-P-1001-02W	Cooling system	Quantity changed in workshop	≈Liters	7.5
		Antifreeze/water	Up to -37°C	50/50
			up to -45°C	55/45
		Service specifications	Specification	Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
			Specification	Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1

Fig 2: Identifying Threaded Stud (102 589 00 34 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Puller (605 589 00 33 00)

Courtesy of MERCEDES-BENZ USA