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Remove/Install Cylinder Head - AR01.30-P-5800MFC

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Engine 260 in model 118, 177, 247 

MODIFICATION NOTES

05.06.2023 Remove slide rail pin (23) and tensioning rail bolt (24). Document reference with new special tool added in operation step 30. AR01.30-P-5800-21MFC
G16140675Courtesy of MERCEDES-BENZ USA

Shown up to model year 2022 

Shown up to model year 2022 

G16140676Courtesy of MERCEDES-BENZ USA

Shown up to model year 2022 

G16140677Courtesy of MERCEDES-BENZ USA
G16140678Courtesy of MERCEDES-BENZ USA
G16140679Courtesy of MERCEDES-BENZ USA
WARNING Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
WARNING Risk of injury  to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
CAUTION Risk of injury  to skin and eyes due to handling of Engine oil. Risk of poisoning  caused by swallowing Engine oil Wear protective gloves, protective clothing and safety glasses.
Do not fill Engine oil into beverage containers.		 AS18.00-Z-0001-01A
Notice  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
Notice  Notes on coolant   AH20.00-P-2080-01KOA
Notice  Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
Notice  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
Notice  Notes on threaded connections with aluminum screws/bolts   AH00.00-P-0006-01RM
  General information on checking valves, valve seats and valve guides   AH05.30-P-1000-02SZ
  General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVINGINSTALLING Remove/install     
1 Remove Engine air intake duct (1).    
2 Remove inerting system line in Engine compartment. Engine 260 in model 118, 177, 247 with code 2U8 (Alternative refrigerant) AR86.10-P-0119MFC
3 Remove camshafts.   AR05.20-P-6992MFC
4 Remove upper heat shields at exhaust gas turbocharger (3).   AR09.40-P-6045MFC
5 Remove catalytic converter (2) at exhaust gas turbocharger (3).   AR49.20-P-0100MFC
6 Remove catalytic converter brackets (2) at crankcase and oil pan.   AR49.20-P-0100MFC
7 Remove support (4) at exhaust gas turbocharger (3). TORQUE SPECIFICATION Nut, turbocharger support brace to turbocharger *BA09.40-P-1004-02G 
8 Unscrew screw (5). TORQUE SPECIFICATION M6 *BA00.10-P-1002-01A 
9 Remove coolant line (6) at exhaust gas turbocharger (3). INSTALLATION IMPORTANT : Replace seals.  
    TORQUE SPECIFICATION Bolt, feed line/return line to turbocharger/crankcase *BA09.40-P-1002-02G 
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Record plug Fig 4
10 Remove oil line (7) at exhaust gas turbocharger (3). INSTALLATION IMPORTANT : Replace seals.  
    TORQUE SPECIFICATION Bolt, feed line/return line to turbocharger/crankcase *BA09.40-P-1002-02G 
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Record plug Fig 4
11 Remove oil line (8) at exhaust gas turbocharger (3). INSTALLATION IMPORTANT : Replace seals.  
    TORQUE SPECIFICATION Bolt, feed line/return line to turbocharger/crankcase *BA09.40-P-1002-02G 
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Record plug Fig 4
12 Remove right oil line bracket at cylinder head (25).    
13.1 Remove charge air pipe from charge air cooler to charge-air distributor (17). Engine 260 in model 118, 177, 247 except code M016 (Uprated Engine)  
      AR09.41-P-1331MFC
13.2 Remove charge air cooler. Engine 260 in model 118, 177, 247 with code M016 (Uprated Engine)  
      AR09.41-P-0105MFC
14 Unscrew screws (9) and place coolant lines (10) to one side. TORQUE SPECIFICATION M6 *BA00.10-P-1002-01A 
15 Unclip wiring harness (11) at cylinder head (25).    
16 Release and disconnect electrical connector (12).    
17 Remove ME-SFI [ME] control unit. Engine 260 in model 118
as of model year 2023		 AR07.08-P-7011MFA
    Engine 260 in model 177, 247 as of model year 2022  
    Engine 260 in model 118
up to model year 2022
Engine 260 in model 177, 247
up to model year 2021		 AR07.08-P-7011MFC
18 Release and disconnect throttle valve actuator electrical connector.   AR07.61-P-1401MFC
19 Release and disconnect electrical connector (13).    
20 Release and disconnect electrical connector at refrigerant compressor with magnetic clutch.   AR83.55-P-5310MFD
21 Release and disconnect electrical connector at lambda sensor downstream of catalytic converter.   AR07.04-P-0085MFC
22 Release and disconnect electrical connector at alternator. Engine 260 in model 118, 177, 247
with code B01 (48V technology)		 AR15.40-P-5060MFA
    Engine 260 in model 118, 177, 247
except code B01 (48V technology)		 AR15.40-P-5032MFC
23 Remove vacuum lines (14, 15, 16) from charge-air distributor (17).    
24 Remove purge valve (18) at bracket (19).    
25 Remove vacuum line (20) at charge-air distributor (17).    
26 Remove coolant line (21) at charge-air distributor (17).   AR20.20-P-7441-01RQ
    SPECIAL TOOL Set of protective covers Fig 6
27 Unclip line for crankcase ventilation system at charge-air distributor (17).    
28 Place Engine wiring harness towards rear over charge-air distributor (17) and secure so that free of tension. NOTES
Do not stretch, crush or kink the electrical wiring harness.
Electrical wiring harness will otherwise be damaged.		  
29 Remove brackets for refrigerant line (22) at body. TORQUE SPECIFICATION Nut, rubber-bonded metal buffer to refrigerant line/body *BA83.30-P-1003-01T 
30 Remove slide rail pin (23) and tensioning rail bolt (24). INSTALLATION IMPORTANT : Thread of slide rail pin (23) and tensioning rail bolt (24) must point outwards. AR01.30-P-5800-21MFC 
    SPECIAL TOOL Insertion tool Fig 7
    SPECIAL TOOL Puller Fig 3
    SPECIAL TOOL Puller Fig 2
31 Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them. Tightening procedure for cylinder head bolts
NOTES Only loosen the cylinder head bolts for a cooled off Engine.
Cylinder head (25) will otherwise be damaged.		 AR01.30-P-5800-01MFC 
    TORQUE SPECIFICATION Bolt, cylinder head to timing case cover *BA01.30-P-1002-01Y 
    TORQUE SPECIFICATION Bolt, cylinder head to crankcase *BA01.30-P-1001-01Y 
    SPECIAL TOOL Tightening angle with magnet Fig 5
32 Remove cylinder head (25). INSTALLATION IMPORTANT : Aid of helper required.
INSTALLATION IMPORTANT : Pay attention to pilot bushings for fixing cylinder head (25) in place.		  
33 Remove mounting bushing from charge air cooler bracket and install inverted from below in charge air cooler bracket. Engine 260 with code M016 (Performance-enhanced Engine) up to Engine number: 260920 30 267521
When replacing cylinder head (25).
INSTALLATION IMPORTANT : Replace screw.		  
34 Remove cylinder head gasket from crankcase. INSTALLATION IMPORTANT : Replace cylinder head gasket.  
35 Seal Engine oil ducts in crankcase with suitable stop plugs (30). IMPORTANT Ensure stop plugs (30) are correctly seated in Engine oil ducts.
IMPORTANT Before removal of stop plugs (30), thoroughly clean area of sealing surface at crankcase with compressed air.		  
    SPECIAL TOOL Record plug Fig 4
36 Clean sealing surfaces at cylinder head (25), timing case cover and crankcase. NOTES
Do not use sharp-edged tools or abrasive paper. Otherwise, damage to the sealing surfaces and then Engine and environmental damage may result.
NOTES
Mechanically processing or cleaning the sealing surfaces, spot grinding with abrasive paper or other abrasive materials to remove seal residue is not permitted.
Even the smallest amounts of aluminum oxide particles, grinding particles or wear debris entering the oil reservoir, the bearing points or the combustion chambers will cause damage and thus result in damage to the Engine/major assemblies.
IMPORTANT The sealing surfaces must feel even after treatment. The sealing surfaces need not be metallic bright; thin layers of firmly adhering silicone sealant may remain.
IMPORTANT Only cleaning with the approved adhesive and sealant remover is permitted.
IMPORTANT Observe processing information from manufacturer.		 AR01.00-P-0050-01A 
    Loctite 7200 *BR00.45-Z-1038-04A 
    Loctite 7063 (400 ml) cleaning spray *BR00.45-Z-1046-04A 
    SPECIAL TOOL Record plug Fig 4
37 Cover threaded holes of cylinder head bolts in crankcase with rags and blow out with compressed air.    
INSPECT Check     
38 Check cylinder head bolts for damage and permissible length. HAND HELD TESTER Cylinder head bolt
If damage or impermissible elongation exists:
↓
Replace cylinder head bolts.		 *BE01.30-P-1001-04B 
39 Check sealing surfaces at cylinder head (25), timing case cover and crankcase for cracks, unevennesses and other damage. INSTALLATION IMPORTANT : The tightening of the cylinder head bolts offsets a slight distortion of cylinder head (25) in the longitudinal or transverse direction.
IMPORTANT Check relevant sealing surfaces of Engine for unevenness, score marks, etc.
If unevenness, score marks, etc. are present:
↓
Replace affected component.		  
40 Install in the reverse order.    
  Concluding tasks     
41 Change Engine oil and Engine oil filter insert.    
REFER TO MAINTENANCE     AP18.00-P-0101MFA
WARNING Risk of accident  from vehicle starting off by itself when Engine running. Risk of injury  (bruises and burns) resulting from working on the Engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
42 Perform Engine test run; in this connection, check Engine for proper operation and leak tightness.    
CYLINDER HEAD/CYLINDER HEAD BOLTS

Number Designation Engine 260
BE01.30-P-1001-04B Cylinder head bolt Thread diameter M 11
Length (L) when new mm 163
Length (L) mm ≤164
-   -
HEADLESS SCREWS: BOLTS AND NUTS, COARSE-PITCH THREAD

Number Designation Model all (4xWD, CAR, smart)
BA00.10-P-1002-01A M6 8.8 Galvanized Nm 9
Phosphated Nm 9
10.9 Galvanized Nm 13
Phosphated Nm 12
12.9 Galvanized Nm 16
Phosphated Nm 14
CYLINDER HEAD

Number Designation Engine 260
BA01.30-P-1001-01Y Bolt, cylinder head to crankcase M11 Stage 1 Nm 10
Stage 2 Nm 40
Stage 3 ∠° 90
Stage 4 ∠° 90
Stage 5 ∠° 90
CYLINDER HEAD

Number Designation Engine 260
BA01.30-P-1002-01Y Bolt, cylinder head to timing case cover M8 Nm 20
TURBOCHARGER

Number Designation Engine 260
BA09.40-P-1002-02G Bolt, feed line/return line to turbocharger/crankcase Stage 1 Nm 8
Stage 2 ∠° 60
TURBOCHARGER

Number Designation Engine 260
BA09.40-P-1004-02G Nut, turbocharger support brace to turbocharger Nm 30
AIR CONDITIONING

Number Designation Model 118 Model 177
BA83.30-P-1003-01T Nut, rubber-bonded metal buffer to refrigerant line/body M6 Nm 8 8
AIR CONDITIONING

Number Designation Model 247
BA83.30-P-1003-01T Nut, rubber-bonded metal buffer to refrigerant line/body M6 Nm 8
Fig 1: Identifying Assembly Tool (000 589 93 63 00)
G16140680Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Puller (605 589 00 33 00)
G16140681Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Puller (270 589 01 33 00)
G16140682Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Record Plug (129 589 00 91 00)
G16140683Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Tightening Angle With Magnet (450 589 00 13 00)
G16140684Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Set Of Protective Covers (001 589 01 91 00)
G16140685Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Insertion Tool (270 589 02 33 00)
G16140686Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1038-04A Loctite 7200 A 010 989 90 71
BR00.45-Z-1046-04A Loctite 7063 (400 ml) cleaning spray A 001 986 71 71 09
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