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Remove/install right cylinder head - AR01.30-P-5780ELB

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ENGINE 157, 278 in MODEL 212, 218 

ENGINE 278 in MODEL 207 

Fig 1: Right Cylinder Head Remove/Install Components
G09973863DANGERNOTESIMPORTANTREMOVINGINSTALLINGIMPORTANTINSTALLATION IMPORTANTSPECIAL TOOLSPECIAL TOOLNOTESINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTREFER TO COMPONENT MODIFICATIONSINSTALLATION IMPORTANTSPECIAL TOOLCLEANNOTESNOTESIMPORTANTREFER TO MAINTENANCEREFER TO MAINTENANCEINSPECTDANGERCourtesy of MERCEDES-BENZ USA
DANGER Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. No parts of the body or limbs should be within the operating area when the components are moving. AS00.00-Z-0011-01A
NOTES Notes on threaded connections with aluminum screws/bolts   AH00.00-P-0006-01RM
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVINGINSTALLING Remove/install     
1 Remove engine with front axle carrier   AR01.10-P-2500ELB
2 Remove cylinder head cover   AR01.20-P-5012ELB
3 Remove intake manifold   AR09.20-P-1310ELB
4 Remove chain tensioner   AR05.10-P-7800ELB
5 Remove camshafts (2) ENGINE 278 in MODEL 207 AR05.20-P-6992FH
ENGINE 157, 278 in MODEL 212, 218
IMPORTANT The camshaft (2) and camshaft positioner (4) must be removed together.		 AR05.20-P-6992EL
6 Pull out sliding rail screw/bolts (5) out of cylinder head (1) INSTALLATION IMPORTANT Apply sealant to slide rail pins (5) before inserting them.  
SPECIAL TOOL Impact extractor Figure
SPECIAL TOOL Threaded bolt Figure
7 Detach turbocharger with exhaust manifold at cylinder head (1)   AR09.40-P-6025ELB
8 Loosen cylinder head bolts in stages in reverse order of tightening procedure and remove them   AR01.30-P-5800-01MMB 
NOTES The cylinder head bolts must only be loosened for a cooled engine.
Stresses can occur in the cylinder head (1) otherwise.
INSTALLATION IMPORTANT Observe tightening procedure for cylinder head (1). Replace cylinder head bolts.		  
TORQUE SPECIFICATION Bolt, cylinder head to cylinder crankcase *BA01.30-P-1001-01X 
TORQUE SPECIFICATION Screw/bolt, cylinder head to timing case cover/crankcase *BA01.30-P-1002-01X 
9 Remove cylinder head (1) from crankcase    
IMPORTANT Notes on sealant path for cylinder crankcase   AH01.40-P-1000-08MM
REFER TO COMPONENT MODIFICATIONS Cylinder head changed   BT01.30-P-0004-01MM
INSTALLATION IMPORTANT Lay new cylinder head gasket on the crankcase. Pay attention to pilot bushing for fixing the cylinder head (1). Apply sealant to crankcase.  
Loctite 5970 sealant *BR00.45-Z-1013-01A 
SPECIAL TOOL Application gun Figure
10 Remove/install check valve for chain tensioner to cylinder head (1) When replacing the cylinder head (1).  
ENGINE 278 in MODEL 207 AR01.30-P-5810FH
ENGINE 157, 278 in MODEL 212, 218 AR01.30-P-5810EL 
CLEAN Clean     
11 Clean sealing surfaces on cylinder head (1), timing case cover and crankcase   AR01.00-P-0050-01A
NOTES Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.		  
Loctite 7200 *BR00.45-Z-1038-04A 
Loctite 7063 cleaning spray (150 ml) *BR00.45-Z-1046-04A 
12 Blow out threaded holes for cylinder head bolts in crankcase with compressed air, and clean off any engine oil and coolant    
13 Check sealing surfaces on cylinder head (1), timing case cover and crankcase for cracks and unevenness NOTES The cylinder head (1) and crankcase must not be re-worked (surface grinding).
The permissible machining tolerances will be exceeded otherwise.
IMPORTANT In the event of any complaint, replace cylinder head (1), timing case cover or crankcase. Any distortion of the cylinder head (1) occurring in the longitudinal or transverse direction will be balanced out again during reassembly through tightening of the cylinder head bolts.		  
14 Install in the reverse order    
15 Change engine oil and oil filter element    
REFER TO MAINTENANCE   ENGINE 157 in MODEL 212, 218 AP18.00-P-0101EWG
REFER TO MAINTENANCE   ENGINE 278 in MODEL 207, 212, 218 AP18.00-P-0101EW
INSPECT Check     
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
16 Carry out an engine test run and check engine and fuel system for leaktightness    
CYLINDER HEAD

Number Designation ENGINE 157 ENGINE 278
BA01.30-P-1001-01X Bolt, cylinder head to M11 cylinder crankcase Stage 1 Nm 20 20
Stage 2 Nm 40 40
Stage 3 ∠° 90 90
Stage 4 ∠° 90 90
Stage 5 ∠° 90 90
CYLINDER HEAD

Number Designation ENGINE 157 ENGINE 278
BA01.30-P-1002-01X Screw/bolt, cylinder head to timing case cover/M7 crankcase Nm 14 14
Fig 2: Identifying Application Gun (112 589 00 25 00)
G09973864Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Threaded Bolt (116 589 01 34 00)
G09973865Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Impact Extractor (116 589 20 33 00)
G09973866Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

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