Remove/Install Cylinder Head - AR01.30-P-5800MSC
Engine 256.9 In Model 167
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 | |
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Remove/install | |||
| 1 | Remove camshaft housing. | AR05.20-P-6997MSC | |
| 2 | Remove exhaust gas turbocharger with exhaust manifold. | AR09.40-P-6036MSC | |
| 3 | Remove coolant return flow line for exhaust gas turbocharger. | AR20.20-P-1050MSC | |
| 4 | Release and disconnect electrical connector at coolant temperature sensor (B11/4). | AR15.60-P-2712MSC | |
| 5 | Remove bracket (5) from cylinder head (1). | *BA15.18-P-1004-01MR | |
| 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 chain tensioner (6). | AR05.10-P-7800MSC | |
| 11 | Remove gearwheel (8). | AR05.10-P-7760MSC | |
| 12 | Remove top slide rail. | AR05.10-P-8421MSC | |
| 13 | Remove screws (9) in reverse order of tightening procedure. | Tightening procedure for cylinder head bolts | AR01.30-P-5800-01MRT |
| *BA01.30-P-1004-01MR T | |||
| 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-2013MSC | |
| 18 | Remove valves. | When replacing the cylinder head (1). | AR05.30-P-3511MSC |
| 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-2712MSC |
| 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. | 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 cylinder head bolts (10) and bolts (9) in crankcase with a rag 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. | ||
| AP18.00-P-0101MRT | |||
| 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 | |
| 28 | Carry out engine test run and check engine for proper operation and leak tightness. | ||
| 29 | Install upper engine cover. | AR01.10-P-2405MSC | |
| 30 | Install lower engine compartment lining. | AR61.20-P-1105ME |
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 |