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

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ENGINE 651 in MODEL 204, 207, 212, 218, 221 

Shown on engine 651.911 

Fig 1: Cylinder Head Remove/Install Components - Shown On Engine 651.911 (1 Of 4)
G09973879Courtesy of MERCEDES-BENZ USA
Fig 2: Cylinder Head Remove/Install Components - Shown On Engine 651.911 (2 Of 4)
G09973880Courtesy of MERCEDES-BENZ USA
Fig 3: Cylinder Head Remove/Install Components - Shown On Engine 651.911 (3 Of 4)
G09973881Courtesy of MERCEDES-BENZ USA
Fig 4: Cylinder Head Remove/Install Components - Shown On Engine 651.911 (4 Of 4)
G09973882Courtesy of MERCEDES-BENZ USA
DANGER Risk of explosion  caused by fuel igniting. Risk of injury  to skin and eyes caused by fuel spraying out at high pressure Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized. AS07.16-Z-0001-01A
DANGER 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
DANGER 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
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
REMOVINGINSTALLING Remove/install     
1 Disconnect battery ground line ENGINE 651 in MODEL 204 AR54.10-P-0003CW
ENGINE 651 in MODEL 207, 212, 218 AR54.10-P-0003EW
ENGINE 651 in MODEL 221 AR54.10-P-0003SX
IMPORTANT Do not connect no-load current retention unit.  
2.1 Remove bottom sections of soundproofing ENGINE 651 in MODEL 204, 207, 212, 218  
ENGINE 651 in MODEL 204.9 AR61.20-P-1105CY
MODEL 204.0/2/3, 207, 212, 218 with ENGINE 651 AR94.30-P-5300EW
2.2 Remove lower engine compartment paneling ENGINE 651 in MODEL 221  
    ENGINE 651 in MODEL 221 AR61.20-P-1105SX
3 Drain off coolant ENGINE 651 in MODEL 204, 207 AR20.00-P-1142CW
    ENGINE 651 in MODEL 212 (except 212.098/298), 218, 221
INSTALLATION NOTES
Do not check the pressure of the cooling system until engine has reached its operating temperature.
Leaks can occur on the cylinder head gasket otherwise.
INSTALLATION IMPORTANT In the case of oil fouling of the cooling and heating system, first fill the cooling and heating system with flushing solution and then remove the oil, see:
↓
Remove oil from cooling and heating system		 AR20.00-P-1142OMA
      AR20.00-P-1250CD
4 Remove cylinder head cover trim    
5 Remove engine air intake duct downstream of air filter ENGINE 651 in MODEL 204, 207, 212, 218, 221 AR09.10-P-8130CD
6 Remove air filter housing ENGINE 651 in MODEL 204, 207, 212, 218, 221 AR09.10-P-1150CD
7 Unclip bracket (12) and remove screw/bolt (13) TORQUE SPECIFICATION Bolt fastening for oil line bracket *BA09.40-P-1004-01P 
8 Remove screw/bolts (15) and take off air filter housing bracket at the front TORQUE SPECIFICATION Screw/bolt, air filter bracket to cylinder head *BA09.10-P-1001-01K 
9 Unhook engine wiring harness from the holder (16), loosen screw/bolts (17) and lay rear air filter housing holder with pressure differential sensor to one side. TORQUE SPECIFICATION Screw/bolt, air filter bracket to cylinder head *BA09.10-P-1001-01K 
10 Unscrew rear lifting eye on cylinder head IMPORTANT Lay lifting eye with oil dipstick guide tube somewhat to one side.  
    Lifting eye/bracket, glow time output stage to cylinder head *BA01.30-P-1004-01V 
11 Remove screw/bolts (24) INSTALLATION IMPORTANT Install new screw/bolts (24) and seal.  
TORQUE SPECIFICATION Flange connection, exhaust manifold to turbocharger *BA09.40-P-1001-01P 
12 Remove temperature sensor upstream of ATL (B19/11)   AR07.04-P-0071CD
13 Remove main fuel filter    
REFER TO MAINTENANCE   ENGINE 651 in MODEL 204 AP47.20-P-0780CWD
REFER TO MAINTENANCE   ENGINE 651 in MODEL 207, 212, 218 AP47.20-P-0780EWD
REFER TO MAINTENANCE   ENGINE 651 in MODEL 221 AP47.20-P-0780SXI
14 Remove screw/bolt (9) and ground cable    
15 Remove screw/bolts (11) and bracket (10) with place glow output stage (N14/3) to one side TORQUE SPECIFICATION Lifting eye/bracket, glow time output stage to cylinder head *BA01.30-P-1004-01V 
16 Remove exhaust gas recirculation valve ENGINE 651 in MODEL 204, 207, 212, 218, 221 AR14.20-P-7662CD
17 Remove screw/bolts (2) and remove bracket (1) for exhaust gas recirculation cooler TORQUE SPECIFICATION Bolt, Y-support brace to cylinder head *BA14.20-P-1007-01K 
18 Remove screw/bolt (5) and lay fuel lines (4) to one side    
19 Remove coolant thermostat ENGINE 651 in MODEL 204, 207, 212 (except 212.098/298), 218, 221 AR20.10-P-2460CD
20 Disconnect coolant hose (18) on fuel filter housing (19)    
21 Disconnect electrical connection at quantity control valve (Y94)    
22 Remove high-pressure line INSTALLATION IMPORTANT Install high-pressure line free of tension. AR07.16-P-1080CD
23 Remove glow plugs IMPORTANT The glow plugs must be removed before removing cylinder head. AR15.20-P-4111CD
24 Set piston of cylinder 1 to top dead center IMPORTANT Rotate engine at crankshaft using a counterholder in direction of engine rotation until the 0° marking on the belt pulley/vibration damper coincides with the marking on the cylinder crankcase.  
SPECIAL TOOL Counterholder Fig 5
25 Remove hydraulic valve compensating elements   AR05.00-P-2011CD
26 Remove screw/bolts (25, 26) TORQUE SPECIFICATION Screw/bolt, cylinder head to timing case cover *BA01.30-P-1001-01V 
27 Loosen screw/bolts (27) in stages and remove   AR01.30-P-5800-01CD 
NOTES Installation: In order to avoid stresses in the cylinder head, loosen screw/bolts (27) on a cooled off engine in reverse order of the tightening procedure.
Otherwise damage may occur.
INSTALLATION IMPORTANT Lubricate screw/bolt (27) at thread and bolt head contact surface and insert. Observe tightening procedure. It is not necessary to retighten the screw/bolts (27).		  
TORQUE SPECIFICATION Screw/bolt, cylinder head to timing case cover *BA01.30-P-1001-01V 
TORQUE SPECIFICATION Bolt, cylinder head to crankcase *BA01.30-P-1002-01V 
28 Check screw/bolts (27) for cylinder head.   AR01.30-P-5800-03T 
Cylinder head bolt *BE01.30-P-1001-04H 
29 Remove cylinder head from cylinder crankcase INSTALLATION IMPORTANT Apply a sealant bead in the sealing area (A) between the timing case and the cylinder crankcase. Fit a new cylinder head gasket on the crankcase. Observe dowel pins (28) for fixing the cylinder head in place. Secure timing chain (29) on tensioning rail (30) for better assembly using a cable bracket.  
Loctite 5970 sealant *BR00.45-Z-1013-01A 
SPECIAL TOOL Application gun Figure
30 Clean contact surfaces and threaded holes IMPORTANT Blow out threaded holes and clean away any oil and water.  
31 Install in the reverse order    
32 Connect STAR DIAGNOSIS, read out fault memory and cleared if required    
REFER TO SELF-DIAGNOSTIC SYSTEMS   Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and cleared in fault memories after completing the work. AD00.00-P-2000-04A
INSPECT Check     
33 Check engine oil level, correct if necessary NOTES The engine oil level must lie between "Min" and "Max".
Engine damage can occur otherwise.		  
34 Check for oil leaks with engine running    
35 Check fuel system for leaks with engine running    
CYLINDER HEAD/CYLINDER HEAD BOLTS

Number Designation ENGINE 651
BE01.30-P-1001-04H Cylinder head bolt Thread diameter M 12
Length (L) when new mm 226 (±0, 5)
Max. length (L) mm 227, 5
-  
TIGHTENING TORQUES, CYLINDER HEAD

Number Designation ENGINE 651
BA01.30-P-1001-01V Screw/bolt, cylinder head to timing case cover M8 Nm 20
TIGHTENING TORQUES, CYLINDER HEAD

Number Designation ENGINE 651
BA01.30-P-1002-01V Bolt, cylinder head to crankcase M12 Stage 1 Nm 10
Stage 2 Nm 50
Stage 3 ∠° 90
Stage 4 ∠° 90
Stage 5 ∠° 90
Stage 6 ∠° 90
TIGHTENING TORQUES, CYLINDER HEAD

Number Designation ENGINE 651
BA01.30-P-1004-01V Lifting eye/bracket, glow time output stage to cylinder head Nm 20
AIR FILTER

Number Designation ENGINE 651
BA09.10-P-1001-01K Screw/bolt, air filter bracket to cylinder head Nm 9
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1001-01P Flange connection, exhaust manifold to turbocharger Stage 1 Nm 20
Stage 2 ∠° 90
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1004-01P Bolt fastening for oil line bracket Nm 9
EXHAUST GAS RECIRCULATION

Number Designation ENGINE 651
BA14.20-P-1007-01K Bolt, Y-support brace to cylinder head Nm 9
Fig 5: Identifying Counter Holder (651 589 00 40 00)
G09973883Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Application Gun (112 589 00 25 00)
G09973884Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
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