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

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ENGINES 642 in MODELS 207, 212, 218 

Fig 1: Cylinder Head Remove/Install Components
G09973890Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER 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
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1 Detach ground line of on-board electrical system battery   AR54.10-P-0003EW
2 Remove bottom section of soundproofing INSTALLATION IMPORTANT Only install bottom sections of soundproofing after engine test run. AR94.30-P-5300EW
3 Drain/collect engine oil INSTALLATION IMPORTANT Replace sealing ring of oil drain screw. AP18.00-P-0101EWO
TORQUE SPECIFICATION *BA01.45-P-1006-01Q 
TORQUE SPECIFICATION *BA18.20-P-1001-01T 
FLUID SPECIFICATION *BF18.00-P-1001-01S 
4 Drain and collect coolant from radiator Model 207 AR20.00-P-1142CW
Model 212, 218 AR20.00-P-1142OGE
5 Remove charge air manifold   AR09.41-P-1310SXI
6 Remove particulate filter   AR14.40-P-1000OGE
7 Remove cylinder head covers   AR01.20-P-5014OGE
8 Remove glow plugs   AR15.20-P-4111CO
9 Remove oil filter housing   AR18.20-P-3471SXI
10 Remove camshafts   AR05.20-P-6992SXI
11 Remove camshaft sprockets   AR05.20-P-6040OM
12 Remove heat shields (3) above exhaust manifolds    
13 Remove high-pressure pump   AR07.02-P-1020SXI
14 Remove slide rail pins (7)   AR01.30-P-5800-04TI 
SPECIAL TOOL Impact extractor Figure
SPECIAL TOOL Threaded stud Figure
SPECIAL TOOL Extractor Figure
15 Loosen cylinder head bolts in stages and remove them NOTES Slacken cylinder head bolts in the reverse sequence to the tightening procedure when the engine has cooled down to prevent warping of cylinder head:
Tightening procedure for cylinder head bolts		 AR01.30-P-5800-01SXI 
INSTALLATION NOTES Observe tightening procedure and tightening specifications for cylinder head bolts to prevent warping of cylinder head, see.
INSTALLATION IMPORTANT Oil cylinder head bolts at thread and bolt head contact surface.		  
TORQUE SPECIFICATION *BA01.30-P-1001-01S 
TORQUE SPECIFICATION *BA01.30-P-1002-01S 
16 Remove right cylinder head (1) and left cylinder head (2)    
IMPORTANT Notes on assigning the cylinder head gaskets   AH01.30-P-1000-06TI
17 Remove exhaust manifold IMPORTANT Only when replacing cylinder heads. AR14.10-P-3915OGE
    TORQUE SPECIFICATION *BA01.30-P-1003-01S 
CLEAN Clean     
18 Clean threaded holes and sealing surfaces NOTES Do not use any sharp-edged tools and no grinding paper otherwise the sealing surfaces will be damaged.
Clean threaded holes and sealing surfaces on crankcase, right cylinder head (1) and left cylinder head (2).		 AR01.00-P-0050-01A
Loctite 7200 *BR00.45-Z-1038-04A 
Loctite 7063 cleaning spray *BR00.45-Z-1046-04A 
INSPECT Checking     
19 Check cylinder head bolts and replace if necessary   AR01.30-P-5800-03TQ 
Cylinder head bolt *BE01.30-P-1001-04A 
20 Install in the reverse order    
21 Read out and erase fault memory using STAR DIAGNOSIS IMPORTANT Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work. AD00.00-P-2000-04A
22 Check for leaks with engine running    
23 Bleed cooling system IMPORTANT Warm up engine to normal operating temperature and fully open heater temperature control (position "hot"). AR20.00-P-1142-04A
SPECIAL TOOL Test cap Fig 4
SPECIAL TOOL Cooler vacuum filling device Fig 5
24 Check/correct engine oil level NOTES In order to avoid measurement errors, vehicle must be parked on an even surface. AR18.00-P-3035-01SXI
IMPORTANT Shut off engine once it has reached operating temperature and wait approx. 5 minutes before checking engine oil level. *BF18.00-P-1001-01S 
CYLINDER HEAD/CYLINDER HEAD BOLTS

Number Designation Engine 642
BE01.30-P-1001-04A Cylinder head bolt Thread diameter M 12
Length (L) when new mm 205
Max. length (L) mm 207
See picture -
CYLINDER HEAD

Number Designation Engine 642
BA01.30-P-1001-01S Bolt, cylinder head to crankcase M8x35 Nm 20
BA01.30-P-1002-01S Bolt, cylinder head to crankcase M12 Stage 1 Nm 10
Stage 2 Nm 60
Stage 3 ∠° 90
Stage 4 ∠° 90
Stage 5 ∠° 90
BA01.30-P-1003-01S Exhaust manifold to cylinder head (stud bolt) Nm 20
OIL PAN

Number Designation Engine 642
BA01.45-P-1006-01Q Oil drain screw on oil pan M12 Nm 30
M24 Nm 45
ENGINE LUBRICATION, OIL FILTER

Number Designation Engine 642
BA18.20-P-1001-01T Threaded cap on oil filter Nm 25
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642.930 with particulate filter up to engine No. 64293040458147 Engine 642.930 with particulate filter starting from engine No. 64293040458148 Engine 642.932/961 with particulate filter
BF18.00-P-1001-01S Engine oil Filling capacity (oil and filter change) Liters 9.5 8.0 8.0
Specifications for Operating Fluids Specifications Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1 Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642.826/830/832/834/836/838/850/852/853/854/856/858/862/868 with particulate filter
BF18.00-P-1001-01S Engine oil Filling capacity (oil and filter change) Liters 8.0
Specifications for Operating Fluids Specifications Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
Fig 2: Identifying Threaded Stud (116 589 01 34 00)
G09973891Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Impact Extractor (116 589 20 33 00)
G09973892Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Test Cap (210 589 00 91 00)
G09973893Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Vacuum Cooling System Filler (285 589 00 21 00)
G09973894Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Puller (605 589 00 33 00)
G09973895Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
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