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

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ENGINES 156 in MODEL 204, 212

Fig 1: Cylinder Head Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Cylinder Head Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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 explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Cylinder head bolts must always be replaced
1	Remove fan unit	Model 204, 207, 172	AR20.40-P-5050CW
2	Remove alternator (G2)		AR15.40-P-5032CMG
3	Remove chain tensioner		AR05.10-P-7800CMG
4	Drain coolant at radiator and cylinder crankcase (12)		AR20.00-P-1142CMG
	Notes on coolant		AH20.00-N-2080-01A
5	Remove catalytic converter from exhaust manifold	Model 204	AR49.10-P-7100CW
5	Remove catalytic converter from exhaust manifold	Model 212	AR49.10-P-7100EW
6	Remove intake manifold (1)		AR09.20-P-1961CMG
7	Remove respective spark plugs		AR15.12-P-1010CMG
8	Rotate engine at crankshaft center bolt in direction of rotation of the engine to a 40° crankshaft angle after top dead center (TDC)	Rotate engine at crankshaft in running direction until scribe mark 40° on pulley/vibration damper corresponds with scribe mark on timing case.
	LH cylinder head
9	Remove cylinder head cover (4)		AR01.20-P-5014CMG
10	Remove intake camshaft adjuster (5) and exhaust camshaft adjuster (6)		AR05.20-P-7201AMG
11	Remove camshaft drive gear (8)		AR05.20-P-7201-07AMG
			*BA05.20-P-1003-02J
			Figure
			Fig 3
12	Remove camshafts		AR05.20-P-6992AMG
13	Remove air shutoff valve (9)	Also remove air line (10) on cylinder head (7). Insert air line (10) before assembling the cylinder head (7). Later assembly is only possible if the power steering pump is removed. Replace gasket.	AR14.30-P-7200CMG
14	Remove oil filter housing (11)		AR18.20-P-3471CMG
15	Pull out guide rail pins		AR01.30-P-5800-04AMG
			Figure
			Figure
16	Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them	To avoid stresses in cylinder head (7), cylinder head bolts must only be loosened when engine has cooled off: ↓ Tightening specifications for cylinder head bolts	AR01.30-P-5800-07AMG
			*BA01.30-P-1002-01U
			*BA01.30-P-1003-01U
			*BA01.30-P-1008-01U
			*BA01.30-P-1009-01U
17	Remove cylinder head (7) from crankcase (12)	Place new cylinder head gasket (12) on crankcase. Pay attention to fitted sleeves for fixing cylinder head (7).
	RH cylinder head
18	Remove cylinder head cover (13)		AR01.20-P-5014CMG
19	Disconnect connector from coolant temperature sensor	The connector is located behind the power steering expansion reservoir.
20	Remove intake camshaft adjuster (5) and exhaust camshaft adjuster (6)		AR05.20-P-7201AMG
21	Remove camshaft drive gear (8)		AR05.20-P-7201-07AMG
			*BA05.20-P-1003-02J
			Figure
			Fig 3
22	Remove camshafts		AR05.20-P-6992AMG
23	Remove air shutoff valve (14)	Only remove air line (15) on cylinder head (7).	AR14.30-P-7200CMG
		Install new gasket
24	Remove guide pulley (16)		*BA13.25-P-1004-01U
25	Remove slide rail pins and tensioning rail pins		AR01.30-P-5800-04AMG
			Figure
			Figure
26	Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them	To avoid stresses in cylinder head (7), cylinder head bolts must only be loosened when engine has cooled off: ↓ Tightening specifications for cylinder head bolts	AR01.30-P-5800-07AMG
			*BA01.30-P-1002-01U
			*BA01.30-P-1003-01U
			*BA01.30-P-1008-01U
			*BA01.30-P-1009-01U
27	Remove cylinder head (7) from crankcase (12)	Place new cylinder head gasket (12) on crankcase. Pay attention to fitted sleeves for fixing cylinder head (7).
	Clean
28	Clean sealing surfaces at crankcase (7) and at cylinder head (12)	Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces. Blow out tapped holes of cylinder head bolts in crankcase (12) with compressed air, and clean off engine oil and coolant.
		Cleaner from package	*BR00.45-Z-1028-04A
	Checking
29	Check sealing surfaces at cylinder head (7) and at crankcase (12) for cracks and unevenness	The cylinder head (7) and crankcase (12) must not be post-worked (face grinding) because production tolerances must not be exceeded.
30	Install in the reverse order
31	Change engine oil and oil filter element
	Engine - oil and filter change	Model 204	AP18.00-P-0101CMG
	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
32	Carry out an engine test run, and check engine and fuel system for leaks
33	Inspecting cooling system for leaks		AR20.00-P-1010CMG
34	Perform new calibration of the sensor rotor for camshaft adjuster using STAR DIAGNOSIS	When removing the camshaft adjuster new calibration is always necessary.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

CAMSHAFT, CAMSHAFT ADJUSTMENT

Number	Designation			Engine 156
BA05.20-P-1003-02J	Bolt connecting bearing pin of camshaft drive gear to crankcase	M6	Nm	9

CYLINDER HEAD

Number	Designation			Engine 156
BA01.30-P-1002-01U	Bolt, cylinder head to crankcase	Stage 1	Nm	10
		Stage 2	Nm	50
		Stage 3	∠°	90
		Stage 4	∠°	90
		Stage 5	∠°	90
BA01.30-P-1003-01U	Bolt, cylinder head to crankcase	M8	Nm	20
BA01.30-P-1008-01U	Cylinder head to timing case chain box on the outside	M8	Nm	20
BA01.30-P-1009-01U	Cylinder head to timing case chain box on the inside	M8	Nm	20

BELT TENSIONING DEVICE

Number	Designation		Engine 156, 159
BA13.25-P-1004-01U	Guide pulley to coolant pump housing (between alternator and smooth guide pulley)	Nm	20

Fig 3: Identifying Threaded Stud (156 589 00 34 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Threaded Stud (116 589 01 34 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package	Adolf Wurth GmbH & Co. KG