Remove/Install Cylinder Head - AR01.30-P-5800MSA
Engine 256.9 in model 213, 238, 257, 290
MODIFICATION NOTES
| 29.03.2021 | Check relevant sealing surfaces of engine for unevenness, score marks, etc. | Operation step 24. |
| 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 | |
| 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 | |
| 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 | |
| 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 | |
| Notice | General information on work on gasoline direct injection system | AH07.00-P-2000-01A | |
| Remove/install | |||
| 1 | Remove camshaft housing. | AR05.20-P-6997MSA | |
| 2 | Remove exhaust gas turbocharger with exhaust manifold. | AR09.40-P-6036MSA | |
| 3 | Remove coolant return flow line for exhaust gas turbocharger. | AR20.20-P-1050MSA | |
| 4 | Release and disconnect electrical connector of coolant temperature sensor (B11/4). | ||
| 5 | Remove bracket (5) from cylinder head. | *BA15.18-P-1004-01MRT | |
| 6 | Remove support plate (2). | *BA07.02-P-1006-01MRT | |
| *BA07.02-P-1004-01MRT | |||
| 7 | Remove coolant feed pipe (3). | *BA20.20-P-1001-02MRT | |
| 8 | Remove screw (4). | *BA01.30-P-1010-01MRT | |
| 9 | Remove spark plugs. | ||
| AP15.10-P-1580E | |||
| 10 | Remove the chain tensioner. | AR05.10-P-7800MSA | |
| 11 | Remove gearwheel (8). | AR05.10-P-7760MSA | |
| 12 | Remove top slide rail. | AR05.10-P-8421MSA | |
| 13 | Remove screws (9) in reverse order of tightening procedure. | Tightening procedure for cylinder head bolts | AR01.30-P-5800-01MRT |
| *BA01.30-P-1004-01MRT | |||
| 14 | Remove cylinder head bolts (10) in reverse order of the tightening procedure. | Tightening procedure for cylinder head bolts | AR01.30-P-5800-01MRT |
| *BA01.30-P-1004-01MRT | |||
| 15 | Remove cylinder head (1). | ||
| General information on checking valves, valve seats and valve guides | AH05.30-P-1000-02SZ | ||
| 16 | Remove cylinder head gasket. | ||
| 17 | Remove hydraulic valve play compensation elements. | AR05.00-P-2013MSA | |
| 18 | Remove valves. | When replacing the cylinder head (1). | AR05.30-P-3511MSA |
| 19 | Remove terminal strips of the exhaust manifold. | When replacing the cylinder head (1). | |
| Tightening pattern for turbocharger | AR09.40-P-6020-10MRT | ||
| *BA14.10-P-1002-02MRT | |||
| 20 | Remove coolant temperature sensor (B11/4). | When replacing the cylinder head (1). | |
| AR15.60-P-2712MSA | |||
| 21 | Remove engine lifting lugs. | When replacing the cylinder head (1). | |
| *BA01.30-P-1009-01MRT | |||
| Clean | |||
| 22 | Clean sealing surfaces of cylinder head (1), timing case cover, and crankcase. | Do not use any sharp-edged tools or abrasive paper. Sealing surfaces will otherwise be damaged. |
|
| Loctite 7063 (400 ml) cleaning spray | *BR00.45-Z-1046-04A | ||
| Loctite 7200 | *BR00.45-Z-1038-04A | ||
| 23 | Cover threaded holes of the cylinder head bolts (10) and screws (9) in the crankcase with rags and blow out with compressed air. | ||
| Check | |||
| 24 | Check sealing surfaces of cylinder head (1), timing case cover and crankcase for cracks and unevennesses. | If unevenness, score marks, etc. are present: ↓ Replace affected component. |
|
| 25 | Check cylinder head bolts (10). | AR01.30-P-5800-03MRT | |
| Cylinder head bolt | *BE01.30-P-1001-04B | ||
| 26 | Install in the reverse order. | ||
| 27 | Change engine oil and oil filter element. | ||
| Engine 256.9 in model 213, 238, 257 (except 257.358), 290 | AP18.00-P-0101MRT | ||
| Engine 256.9 in model 257.358 | AP18.00-P-0101MRS |
CYLINDER HEAD/CYLINDER HEAD BOLTS
| Number | Designation | Engine 256 | ||
|---|---|---|---|---|
| BE01.30-P-1001-04B | Cylinder head bolt | Thread diameter | M | 11 |
| Length (L) when new | mm | 158 ± 0, 5 | ||
| Length (L) | mm | ≤ 159, 5 | ||
| - | - | |||
CYLINDER HEAD
| Number | Designation | Engine 256.9 | |||
|---|---|---|---|---|---|
| BA01.30-P-1004-01MRT | Screw, cylinder head to crankcase/timing case | M8 | Nm | 20 | |
| M11 | Stage 1 | Nm | 10 | ||
| Stage 2 | Nm | 40 | |||
| Stage 3 | ∠° | 90 | |||
| Stage 4 | ∠° | 90 | |||
| Stage 5 | ∠° | 90 | |||
CYLINDER HEAD
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA01.30-P-1009-01MRT | Bolt, lifting eye to cylinder head | Nm | 29 |
CYLINDER HEAD
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA01.30-P-1010-01MRT | Screw/bolt, thermostat coolant connection pipe to cylinder head | Nm | 8 |
HIGH PRESSURE FUEL PUMP, HIGH PRESSURE FUEL PUMP HOUSING
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA07.02-P-1004-01MRT | Screw, support plate above fuel high-pressure pump to cylinder head | Nm | 8 |
HIGH PRESSURE FUEL PUMP, HIGH PRESSURE FUEL PUMP HOUSING
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA07.02-P-1006-01MRT | Screw, shield to fuel high-pressure pump housing/support plate | Nm | 8 |
EXHAUST MANIFOLD
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA14.10-P-1002-02MRT | Screw, exhaust manifold (exhaust gas turbocharger) strip clamp to cylinder head | Nm | 20 |
12 V ON-BOARD ELECTRICAL SYSTEM ENGINE WIRING HARNESS
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA15.18-P-1004-01MRT | Screw, electrical connector bracket to cylinder head | Nm | 8 |
ENGINE RADIATOR, COOLANT HOSES AND LINES
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA20.20-P-1001-02MRT | Screw, coolant feed pipe to cylinder head/crankcase | Nm | 8 |
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 |