LEMON Manuals: Even more car manuals for everyone
Home >> Smart >> 2015 >> Fortwo Electric Drive, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 15 (Complete Engine - 212 Chassis - 4 Of 5) >> Testing & Repair >> Remove/install right cylinder head >> Remove/install right cylinder head - AR01.30-P-5780ELS

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

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

ENGINE 276.8 in MODEL 207, 212, 218 

Shown on model 212 

Fig 1: Right Cylinder Head Remove/Install Components - Shown On Model 212 (1 Of 3)
G09973867Courtesy of MERCEDES-BENZ USA
Fig 2: Right Cylinder Head Remove/Install Components - Shown On Model 212 (2 Of 3)
G09973868Courtesy of MERCEDES-BENZ USA
Fig 3: Right Cylinder Head Remove/Install Components - Shown On Model 212 (3 Of 3)
G09973869Courtesy of MERCEDES-BENZ USA
DANGER Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
DANGER 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
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 the right cylinder head cover   AR01.20-P-5012ELS
2 Remove exhaust gas recirculation valve ENGINE 276.8 in MODEL 207, 212, 218 with CODE 920 (Direct petrol injection with stratified charging) AR14.20-P-7662ELS
3 Remove centrifuge and oil separator   AR01.20-P-2100ELS
4 Detach holder (2) from crankcase (14)    
5 Detach right exhaust pipe at transmission holder TORQUE SPECIFICATION Bolt/nut, exhaust system bracket to exhaust system *BA49.10-P-1024-01AE 
6 Unfasten clamp (8) and detach exhaust pipe on ATL INSTALLATION IMPORTANT The dowel pin on exhaust pipe must be set in the notch on the ATL. After screwing down the clamp (8) using the prescribed torque there should be no gap anymore on the clamp lock. 
INSTALLATION IMPORTANT Replace clamp (8) and seal between exhaust pipe and ATL.		  
    TORQUE SPECIFICATION Bolt, pipe clamp to exhaust gas turbocharger *BA49.10-P-1050-01AE 
7 Detach heat shield (3) TORQUE SPECIFICATION Bolt/nut for shield attachment *BA09.40-P-1011-01W 
8 Detach oil return line (7) on turbocharger TORQUE SPECIFICATION Bolt, oil return flow line to turbocharger *BA09.40-P-1006-01W 
9 Remove coolant return line (5) TORQUE SPECIFICATION Bolt, coolant feed/return line to turbocharger *BA09.40-P-1008-01W 
10 Detach right charge air pipe (6) and left charge air pipe from right and left turbocharger   AR09.41-P-6819ELS
11 Detach charge air cooler from throttle valve actuator and pull to the front with attached coolant hoses   AR09.41-P-6819ELS
12 Detach vacuum line on vacuum unit (4)    
13 Disconnect electrical connection at right bypass air switchover valve (Y101/2)    
14 Detach wide open throttle vent line (9) at turbocharger TORQUE SPECIFICATION Screw/bolt, vent line from oil separator to turbocharger *BA01.20-P-1007-01L 
15 Remove coolant thermostat MODEL 207 with ENGINE 276.8 AR20.10-P-2460FH
MODEL 212, 218 with ENGINE 276.8 AR20.10-P-2460ELS
16 Remove coolant pipe (13) INSTALLATION IMPORTANT Install new coolant pipe (13).  
17 Remove chain tensioner MODEL 207 with ENGINE 276.8 AR05.10-P-7800FH
MODEL 212, 218 with ENGINE 276.8 AR05.10-P-7800EL
18 Pull slide rail bolt (12) out of cylinder head (11R) SPECIAL TOOL Threaded bolt Figure
SPECIAL TOOL Impact extractor Figure
19 Remove camshaft positioner for exhaust camshaft (11A)   AR05.20-P-7201ELS
20 Remove camshafts (11A, 11E) ENGINE 276.8 in MODEL 207 AR05.20-P-6992FH
ENGINE 276.8 in MODEL 212, 218
IMPORTANT The camshaft positioner can remain on the intake camshaft (11E).		 AR05.20-P-6992EL
21 Loosen cylinder head bolts (11S) in stages in reverse order of tightening procedure and remove them Tightening procedure for cylinder head bolts AR01.30-P-5800-01MMA 
NOTES Only loosen the cylinder head bolts (11S) for a cooled off engine.
The cylinder head on the right (11R) can be deformed by tension otherwise.
INSTALLATION IMPORTANT Observe tightening procedure.
INSTALLATION IMPORTANT Replace cylinder head bolts (11S).		  
TORQUE SPECIFICATION Bolt, cylinder head to crankcase *BA01.30-P-1001-01W 
TORQUE SPECIFICATION Bolt, cylinder head to timing case cover *BA01.30-P-1002-01W 
22 Take right cylinder head (11R) off crankcase (14)    
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 Apply sealant to crankcase (14).
INSTALLATION IMPORTANT Fit new cylinder head gasket onto the crankcase (14). Pay attention to the pilot bushing for fixing the cylinder head on the right (11R).		  
Loctite 5970 sealant *BR00.45-Z-1013-01A 
SPECIAL TOOL Application gun Figure
23 Install check valve for chain tensioner on right cylinder head (11R) When replacing the right cylinder head (11R)  
MODEL 207 with ENGINE 276.8 AR01.30-P-5810FH
MODEL 212, 218 with ENGINE 276.8 AR01.30-P-5810EL 
24 Detach turbocharger from right cylinder head (11R) When replacing the right cylinder head (11R) AR09.40-P-6025ELS
CLEANING Clean     
25 Clean sealing surfaces at right cylinder head (11R) and crankcase (14)   AR01.00-P-0050-01A
NOTES Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.		  
Loctite 7063 cleaning spray (150 ml) *BR00.45-Z-1046-04A 
Loctite 7200 *BR00.45-Z-1038-04A 
26 Blow out threaded holes of cylinder head bolts (11S) in crankcase (14) with compressed air and clean off engine oil and coolant.    
27 Check sealing surfaces on right cylinder head (11R) and cylinder crankcase (14) for cracks and unevenness NOTES The right cylinder head (11R) or the crankcase (14) must not be reworked (flat grinding).
The right cylinder head (11R) or the cylinder crankcase (14) may be destroyed otherwise due to exceeding the machining tolerances.		  
28 Install in the reverse order    
29 Change engine oil and oil filter element    
REFER TO MAINTENANCE     AP18.00-P-0101CWZ
INSPECT Check     
30 Check basic position of the exhaust camshaft (11A) and intake camshaft (11E) ENGINE 276.8 in MODEL 207 AR05.20-P-6010FHA
ENGINE 276.8 in MODEL 212, 218 AR05.20-P-6020EL
31 Check engine cooling system for leaktightness ENGINE 276.8 in MODEL 207 AR20.00-P-1010ELA
ENGINE 276.8 in MODEL 212, 218 AR20.00-P-1010EL
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
32 Carry out an engine test run and check engine and fuel system for leaktightness    
CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number Designation ENGINE 276
BA01.20-P-1007-01L Screw/bolt, vent line from oil separator to turbocharger Nm 9
CYLINDER HEAD

Number Designation ENGINE 276
BA01.30-P-1001-01W Bolt, cylinder head to M11 crankcase Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 ∠° 90
Stage 4 ∠° 90
CYLINDER HEAD

Number Designation ENGINE 276
BA01.30-P-1002-01W Bolt, cylinder head to timing case cover M7 Nm 14
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1006-01W Bolt, oil return flow line to turbocharger Nm 11
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1008-01W Bolt, coolant feed/return line to turbocharger Nm 9
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1011-01W Bolt/nut for shield attachment M6 Nm 9
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1024-01AE Bolt/nut, exhaust system bracket to exhaust system Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 271, 272, 273, 276, 278 in MODEL 207
BA49.10-P-1024-01AE Bolt/nut, exhaust system bracket to exhaust system Nm 20
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1050-01AE Bolt, pipe clamp to exhaust gas turbocharger Nm 15 15
EXHAUST SYSTEM

Number Designation ENGINE 271, 272, 273, 276, 278 in MODEL 207
BA49.10-P-1050-01AE Bolt, pipe clamp to exhaust gas turbocharger Nm 15
Fig 4: Identifying Application Gun (112 589 00 25 00)
G09973870Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Threaded Bolt (116 589 01 34 00)
G09973871Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Impact Extractor (116 589 20 33 00)
G09973872Courtesy 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
scientia non olet · About LEMON Manuals