AutoZone 2005 Mercedes Benz SL55 AMG 5.5L SFI SC 8cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Cylinder Head | AutoZone.com

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    2005 Mercedes Benz SL55 AMG 5.5L SFI SC 8cyl

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    Liberty, Wrangler, 1997-2005

    Cylinder Head

    Print

    Removal & Installation



    2.5L Engines
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove or disconnect the following:
      NOTE
      Keep valvetrain components in order for reassembly.



      Negative battery cable
       
      Crankcase Ventilation (CCV) hoses
       
      Air cleaner assembly
       
      Valve cover
       



      Rocker arms
       
      Pushrods
       
      Accessory drive belt
       
      A/C compressor and bracket, if equipped
       
      Power steering pump and bracket, if equipped
       
      Fuel line
       
      Combination manifold
       
      Thermostat housing coolant hoses
       
      Spark plugs
       
      Engine Coolant Temperature (ECT) sensor connector
       
      Cylinder head
       

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Alignment dowel locations-2.5L engine



    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-2.5L engine


    WARNING
    Cylinder head bolts may only be reused one time. If reusing a cylinder head bolt, place a paint mark on the bolt after installation. If a cylinder head bolt has a paint mark, discard it and use a new bolt.

    1. Fabricate two alignment dowels from old cylinder head bolts. Cut the hex head off of the bolts, and cut a slot in each dowel to ease removal.
    2.  
    3. Install or connect the following:

      One dowel in bolt hole No. 8, and one dowel in bolt hole No. 10.
       
      Cylinder head and gasket.
       
      Cylinder head bolts except for No 8 and No 10. Coat the threads of bolt No. 7 with Loctite® 592 sealant.
       

    4.  
    5. Remove the alignment dowels and install the No. 8 and No. 10 head bolts.
      WARNING
      During the final tightening sequence, bolt No. 7 will be tightened to a lower torque value than the rest of the bolts. Do not overtighten bolt No. 7.

    6.  
    7. Tighten the cylinder head bolts, in sequence, as follows:
      1. Step 1: 22 ft. lbs. (30 Nm)
      2.  
      3. Step 2: 45 ft. lbs. (61 Nm)
      4.  
      5. Step 3: 45 ft. lbs. (61 Nm)
      6.  
      7. Step 4: Bolts 1-6 to 110 ft. lbs. (149 Nm)
      8.  
      9. Step 5: Bolt 7 to 100 ft. lbs. (136 Nm)
      10.  
      11. Step 6: Bolts 8-10 to 110 ft. lbs. (149 Nm)
      12.  
      13. Step 7: Repeat steps 4, 5 and 6
      14.  

    8.  
    9. Install or connect the following:

      ECT sensor connector
       
      Spark plugs
       
      Thermostat housing coolant hoses
       
      Combination manifold
       
      Fuel line
       
      Power steering pump and bracket, if equipped
       
      A/C compressor and bracket, if equipped
       
      Accessory drive belt
       
      Pushrods and rocker arms in their original positions
       
      Valve cover
       
      Air cleaner assembly
       
      CCV hoses
       
      Negative battery cable
       

    10.  
    11. Fill and bleed the cooling system.
    12.  
    13. Start the engine, check for leaks and repair if necessary.
    14.  

    2.8L Engine
    1. Disconnect negative battery cable.
    2.  
    3. Remove engine cover and bracket.
    4.  
    5. Drain cooling system.
    6.  
    7. Evacuate A/C.
    8.  
    9. Remove radiator core support.
    10.  
    11. Remove cooling fan and fan drive viscous clutch assembly.
    12.  
    13. Remove accessory drive belt.
    14.  
    15. Remove accessory drive belt tensioner and both idler pulleys, Idler pulley bolts are L.H. thread.
    16.  
    17. Remove power steering pump pulley.
    18.  
    19. Remove front engine lift bracket.
    20.  
    21. Remove cooling fan support.
    22.  
    23. Remove generator and support bracketing.
    24.  
    25. Remove viscous heater.
    26.  
    27. Rotate the engine to 90 degrees ATDC, or the 3 o-clock position at the crankshaft hub.
    28.  
    29. Remove vibration damper.
    30.  
    31. Disconnect main engine wiring harness connectors from right inner wheel housing.
    32.  
    33. Disconnect main engine wiring harness ancillary components and set harness aside.
    34.  
    35. Remove air cleaner housing.
    36.  
    37. Remove exhaust manifold heat shield .
    38.  
    39. Remove turbocharger heat shield retaining bolt and position shield aside .
    40.  
    41. Remove turbocharger oil supply line from turbocharger.
    42.  
    43. Raise and support vehicle.
    44.  
    45. Disconnect exhaust stabilizer bracket at lower exhaust manifold .
    46.  
    47. Disconnect exhaust system bracket at transmission cross member.
    48.  
    49. Lower the vehicle and remove the exhaust manifold retaining nuts.
    50.  
    51. Slide the exhaust manifold and turbocharger off of exhaust manifold studs .
    52.  
    53. Remove coolant hoses at thermostat housing.
    54.  
    55. Disconnect fuel return hose from fuel injectors and set aside.
    56.  
    57. Remove fuel injector pressure lines.
    58.  
    59. Disconnect fuel pump high pressure line at fuel rail.
    60.  
    61. Disconnect oil level indicator tube from intake manifold.
    62.  
    63. Disconnect brake booster line bracket from intake manifold and position aside.
    64.  
    65. Remove fuel injectors.
      CAUTION
      Before removing the cylinder head cover/ intake manifold or timing belt the crankshaft hub must placed at 90° ATDC or the 3 O-clock position. Failure to do so could result in valve and/or piston damage during reassembly.

    66.  
    67. Remove timing belt outer cover.
    68.  
    69. Remove timing belt.
    70.  
    71. Using VM.1085, remove both camshaft gears.
    72.  
    73. Remove timing belt inner cover.
    74.  
    75. Remove cylinder head cover/intake manifold.
    76.  
    77. Remove rocker arm and lifter assemblies from cylinder head. Be sure to keep in same order as removed.
    78.  
    79. Remove cylinder head cover/intake manifold gasket from cylinder head.
    80.  
    81. Disconnect glow plug and engine coolant temperature electrical connectors.
    82.  
    83. Remove turbocharger outlet to charge air cooler hose.
    84.  
    85. Remove cylinder head bolts.
    86.  
    87. Remove cylinder head assembly from engine block .
    88.  

    To install:


    CAUTION
    Piston protrusion must be measured to determine cylinder head gasket thickness if one or more cylinder liners have been replaced.


    NOTE
    If cylinder liner(s) have not been removed, the same thickness head gasket that was removed can be used.

    1. Clean and inspect gasket mating surfaces.
    2.  
    3. Position correct head gasket on engine block.
    4.  
    5. Place cylinder head on engine block.
      CAUTION
      New cylinder head bolts must be used. Do not lubricate new cylinder head bolts. They already are coated with an anti scuff treatment.

    6.  
    7. Tighten cylinder head bolts following procedure below.
    8.  
    9. Cylinder Head Bolt Torquing Procedure
      1. Tighten all cylinder head bolts to 22 ft. lbs. (30 Nm) starting from the center bolts, following the cylinder head scheme and the following sequence: 3-2-1-10-9-8-7-6-5-4-11-12-13-14-15-16-17-18.
      2.  
      3. Without loosening any bolts, starting from the center bolts, tighten each bolt an additional 75° in the following sequence: 10-9-8-7-6-5-4-3-2-1.
      4.  
      5. Tighten the lateral cylinder head bolts an additional 50° in the following sequence: 11-12-13-14-15- 16-17-18.
      6.  
      7. Finally tighten all bolts an additional 75° in the following sequence: 10-9-8-7-6-5-4-3-2-1-11-12-13-14- 15-16-17-18.
      8.  

    10.  
    11. Slide exhaust manifold and turbocharger on exhaust manifold studs .
    12.  
    13. Install exhaust manifold retaining nuts. Tighten the nuts to. 27 ft. lbs. (36 Nm) in a cross sequence beginning in the middle and working outward, then perform the tightening sequence to the exhaust manifold nuts again.
    14.  
    15. Install exhaust manifold heat shield. Torque bolts to 217 inch lbs. (24.5 Nm).
    16.  
    17. Install turbocharger outlet to charge air cooler pipe.
    18.  
    19. Install upper radiator hose.
    20.  
    21. Connect glow plug and coolant temperature sensor electrical connectors.
    22.  
    23. Install new cylinder head cover/intake manifold gasket.
    24.  
    25. Install rocker arm and lifter assemblies. Be sure to put rocker arm and lifter assemblies in same location as removed.
      CAUTION
      Care must be taken not to knock the rocker arms off of the valves when installing the cylinder head cover/intake manifold.

    26.  
    27. Install cylinder head cover/intake manifold.
    28.  
    29. Install timing belt inner cover.
      NOTE
      Make sure the crankshaft is rotated to the 90 degree ATCD, or the 3 O-clock position.

    30.  
    31. Install both camshaft gears and tighten bolts finger tight.
    32.  
    33. Install timing belt.
    34.  
    35. Using VM.1085, torque cam gear retaining bolts to 108 Nm.
    36.  
    37. Install timing belt outer cover.
    38.  
    39. Remove both camshaft locking pins at this time.
    40.  
    41. Install fuel injectors.
    42.  
    43. Install brake booster line bracket to intake manifold.
    44.  
    45. Install oil level indicator tube to intake manifold.
    46.  
    47. Connect fuel pump high pressure line to fuel rail.
    48.  
    49. Install fuel injector pressure lines.
    50.  
    51. Connect fuel return hose to fuel injectors.
    52.  
    53. Connect engine coolant hoses to thermostat housing.
    54.  
    55. Raise vehicle.
    56.  
    57. Reconnect exhaust system bracket at transmission cross member.
    58.  
    59. Connect exhaust stabilizer bracket to lower exhaust manifold .
    60.  
    61. Install turbocharger oil supply line to turbocharger.
    62.  
    63. Lower vehicle.
    64.  
    65. Install turbocharger heat shield.
    66.  
    67. Install exhaust manifold heat shield.
    68.  
    69. Install air cleaner housing.
    70.  
    71. Install main engine wiring harness and connect all ancillary electrical components.
    72.  
    73. Install viscous heater.
    74.  
    75. Install vibration damper.
    76.  
    77. Install generator.
    78.  
    79. Install cooling fan support.
    80.  
    81. Install front engine lift bracket.
    82.  
    83. Install power steering pump pulley.
    84.  
    85. Install accessory drive belt tensioner and both idler pulleys. Idler pulley retaining bolts are L.H. Thread.
    86.  
    87. Install accessory drive belt.
    88.  
    89. Install cooling fan and fan drive viscous clutch assembly.
    90.  
    91. Install upper radiator core support.
    92.  
    93. Refill cooling system.
    94.  
    95. Install engine cover and bracket.
    96.  
    97. Connect negative battery cable.
    98.  
    99. Start engine and allow to warm. Turn engine off and inspect for leaks.
    100.  

    3.7L Engine
    Left Side
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Properly relieve the fuel system pressure.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Exhaust Y-pipe
       
      Intake manifold
       
      Cylinder head cover
       
      Engine cooling fan and shroud
       
      Accessory drive belt
       
      Power steering pump
       

    8.  
    9. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V6 marks on the camshaft sprockets are at 12 o-clock as shown.

      Crankshaft damper
       
      Front cover

      Click image to see an enlarged view

      Fig. Camshaft sprocket timing marks-3.7L

       

    10.  
    11. Lock the secondary timing chain to the idler sprocket with Timing Chain Locking tool 8429.

      Click image to see an enlarged view

      Fig. Camshaft locking tool-3.7L

    12.  
    13. Matchmark the secondary timing chain one link on each side of the V6 mark to the camshaft sprocket.
      NOTE
      The cylinder head is retained by twelve bolts. Four of the bolts are smaller and are at the front of the head.



      Left secondary timing chain tensioner
       
      Cylinder head access plug
       
      Secondary timing chain guide
       
      Camshaft sprocket
       
      Cylinder head
       

    14.  

    To install:

    Click image to see an enlarged view

    Fig. Examine the head bolts for signs of stretching-3.7L engine

    1. Check the cylinder head bolts for signs of stretching and replace as necessary.
    2.  
    3. Lubricate the threads of the 11mm bolts with clean engine oil.
    4.  
    5. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive.
    6.  
    7. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
      1. Step 1: Bolts 1-8 to 20 ft. lbs. (27 Nm)
      2.  
      3. Step 2: Bolts 1-10 verify torque without loosening
      4.  
      5. Step 3: Bolts 9-12 to 10 ft. lbs. (14 Nm)
      6.  
      7. Step 4: Bolts 1-8 plus 1 / 4 (90 degree) turn
      8.  
      9. Step 5: Bolts 9-12 to 19 ft. lbs. (26 Nm)

        Click image to see an enlarged view

        Fig. Cylinder head bolt torque sequence-3.7L

      10.  

    8.  
    9. Install or connect the following:

      Camshaft sprocket. Align the secondary chain matchmarks and tighten the bolt to 90 ft. lbs. (122 Nm).
       
      Secondary timing chain guide
       
      Cylinder head access plug
       
      Secondary timing chain tensioner.
       

    10.  
    11. Remove the Timing Chain Locking tool.
    12.  
    13. Install or connect the following:

      Front cover
       
      Crankshaft damper. Torque the bolt to 130 ft. lbs. (175 Nm).
       
      Power steering pump
       
      Accessory drive belt
       
      Engine cooling fan and shroud
       
      Cover
       
      Intake manifold
       
      Exhaust Y-pipe
       
      Negative battery cable
       

    14.  
    15. Fill and bleed the cooling system.
    16.  
    17. Start the engine, check for leaks and repair if necessary.
    18.  

    Right Side
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Properly relieve the fuel system pressure.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Exhaust Y-pipe
       
      Intake manifold
       
      Valve cover
       
      Engine cooling fan and shroud
       
      Accessory drive belt
       
      Oil fill housing
       
      Power steering pump
       

    8.  
    9. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V6 marks on the camshaft sprockets are at 12 o-clock as shown.

      Click image to see an enlarged view

      Fig. Crankshaft timing marks-3.7L engine



      Click image to see an enlarged view

      Fig. Camshaft positioning-3.7L engine

    10.  
    11. Remove or disconnect the following:

      Crankshaft damper
       
      Front cover
       

    12.  
    13. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8429.
    14.  
    15. Matchmark the secondary timing chains to the camshaft sprockets.
    16.  
    17. Remove or disconnect the following:
      NOTE
      Each cylinder head is retained by 8 11mm bolts and four 8mm bolts.



      Secondary timing chain tensioners
       
      Cylinder head access plugs
       
      Secondary timing chain guides
       
      Camshaft sprockets
       
      Cylinder heads
       

    18.  

    To install:

    1. Check the cylinder head bolts for signs of stretching and replace as necessary.
    2.  
    3. Lubricate the threads of the 11mm bolts with clean engine oil.
    4.  
    5. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive.
    6.  
    7. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
      1. Step 1: Bolts 1-8 to 20 ft. lbs. (27 Nm)
      2.  
      3. Step 2: Bolts 1-10 verify torque without loosening
      4.  
      5. Step 3: Bolts 9-12 to 10 ft. lbs. (14 Nm)
      6.  
      7. Step 4: Bolts 1-8 plus 1 / 4 (90 degree) turn
      8.  
      9. Step 5: Bolts 9-12 to 19 ft. lbs. (26 Nm)
      10.  

    8.  
    9. Install or connect the following:

      Camshaft sprockets. Align the secondary chain matchmarks and tighten the bolts to 90 ft. lbs. (122 Nm).
       
      Secondary timing chain guides
       
      Cylinder head access plugs
       
      Secondary timing chain tensioners.
       

    10.  
    11. Remove the Timing Chain Locking tool.
    12.  
    13. Install or connect the following:

      Front cover
       
      Crankshaft damper. Torque the bolt to 130 ft. lbs. (175 Nm).
       
      Rocker arms
       
      Power steering pump
       
      Oil fill housing
       
      Accessory drive belt
       
      Engine cooling fan and shroud
       
      Valve covers
       
      Intake manifold
       
      Exhaust Y-pipe
       
      Negative battery cable
       

    14.  
    15. Fill and bleed the cooling system.
    16.  
    17. Start the engine, check for leaks and repair if necessary.
    18.  

    4.0L Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect the battery negative cable.
      CAUTION
      Do not remove the cylinder block drain plugs or loosen the radiator drain cock with the system hot and pressurized because serious burns from the coolant can occur.

    4.  
    5. Drain the coolant and disconnect the hoses at the engine thermostat housing and the water pump inlet. DO NOT waste reusable coolant. If the solution is clean and is being drained only to service the engine or cooling system, drain the coolant into a clean container for reuse.
    6.  
    7. Remove the air cleaner assembly.
    8.  
    9. Remove the cylinder head cover.
    10.  
    11. Remove the capscrews, bridge and pivot assemblies and rocker arms.
    12.  
    13. Remove the push rods. Retain the pushrods, bridges, pivots and rocker arms in the same order as removed.
    14.  
    15. Remove the accessory drive belt.
    16.  
    17. Remove the A/C compressor mounting bolts and secure the compressor to the side.
    18.  
    19. Remove the power steering pump and bracket from the intake manifold and water pump. Set the pump and bracket aside. DO NOT disconnect the hoses.
    20.  
    21. Perform the Fuel System Pressure Release procedure.
    22.  
    23. Disconnect the fuel supply line at the fuel rail.
    24.  
    25. Remove the intake and exhaust manifolds from the engine cylinder head.
    26.  
    27. Disconnect the coil rail electrical connectors and remove the coil rail.
    28.  
    29. Remove spark plugs.
    30.  
    31. Disconnect the temperature sending unit wire connector.
    32.  
    33. Remove the engine cylinder head bolts.
      NOTE
      Bolt No.14 cannot be removed until the head is moved forward. Pull bolt No.14 out as far as it will go and then suspend the bolt in this position (tape around the bolt).

    34.  
    35. Remove the engine cylinder head and gasket.
    36.  
    37. If this was the first time the bolts were removed, put a paint dab on the top of the bolt. If the bolts have a paint dab on the top of the bolt or it isn-t known if they were used before, discard the bolts.
    38.  
    39. Stuff clean lint free shop towels into the cylinder bores.
    40.  

    To install:

    The engine cylinder head gasket may be a composition gasket. This gasket is to be installed DRY. Do not use a gasket sealing compound on the gasket. If the engine cylinder head is to be replaced and the original valves used, measure the valve stem diameter. Only standard size valves can be used with a service replacement engine cylinder head unless the replacement head valve stem guide bores are reamed to accommodate oversize valve stems. Remove all carbon buildup and reface the valves.

    1. Remove the shop towels from the cylinder bores. Coat the bores with clean engine oil.
    2.  
    3. Position the engine cylinder head gasket (with the numbers facing up) using the alignment dowels in the cylinder block, to position the gasket.
      WARNING
      Engine cylinder head bolts should be reused only once. Replace the head bolts if they were used before or if they have a paint dab on the top of the bolt.

    4.  
    5. With bolt No.14 held in place (tape around bolt), install the engine cylinder head over the same dowels used to locate the gasket. Remove the tape from bolt No.14.
    6.  
    7. Coat the threads of stud bolt No.11 with Loctite® 592 sealant, or equivalent.
    8.  
    9. Tighten the engine cylinder head bolts in sequence according to the following procedure.
      WARNING
      During the final tightening sequence, bolt No.11 will be tightened to a lower torque than the rest of the bolts. DO NOT overtighten bolt No.11.



      Bolts 1 through 14 to 22 ft. lbs. (30 Nm).
       
      Bolts 1 through 14 to 45 ft. lbs. (61 Nm).
       
      Check all bolts to verify they are set to 45 ft. lbs. (61 Nm).
       
      Bolts 1 through 10 to 110 ft. lbs. (149 Nm).
       
      Bolt 11 to 100 ft. lbs. (135 Nm).
       
      Bolts 12 through 14 to 110 ft. lbs. (149 Nm).
       
      Check all bolts in sequence to verify the correct torque.
       
      If not already done, clean and mark each bolt with a dab of paint after tightening. Should you encounter bolts which were painted in an earlier service operation, replace them.
       

    10.  
    11. Install the spark plugs.
    12.  
    13. Connect the temperature sending unit wire connector.
    14.  
    15. Install the ignition coil rail and coil rail electrical connectors.
    16.  
    17. Install the intake and exhaust manifolds.
    18.  
    19. Install the fuel line and the vacuum advance hose.
    20.  
    21. Attach the power steering pump and bracket.
    22.  
    23. Install the push rods, rocker arms, pivots and bridges in the order they were removed.
    24.  
    25. Install the engine cylinder head cover.
    26.  
    27. Attach the air conditioner compressor mounting bracket to the engine cylinder head and block. Tighten the bolts to 30 ft. lbs. (40 Nm) torque.
    28.  
    29. Attach the air conditioning compressor to the bracket. Tighten the bolts to 20 ft. lbs. (27 Nm) torque.
      WARNING
      The serpentine drive belt must be routed correctly. Incorrect routing can cause the water pump to turn in the opposite direction causing the engine to overheat.

    30.  
    31. Install the serpentine drive belt.
    32.  
    33. Install the air cleaner and ducting.
    34.  
    35. Connect the hoses to the engine thermostat housing and fill the cooling system to the specified level.
    36.  
    37. The automatic transmission throttle linkage and cable must be adjusted after completing the engine cylinder head installation.
    38.  
    39. Install the temperature sending unit and connect the wire connector.
    40.  
    41. Position the A/C compressor into the engine compartment.
    42.  
    43. Install the bolts and nut that secure the A/C compressor to the engine. Tighten the bolts and nut fastening the compressor to the cylinder block to 35-50 ft. lbs. (45-65 Nm). Tighten the bolts fastening the rear brace to the compressor and cylinder block to 30-40 ft. lbs. (40-55 Nm).
    44.  
    45. Connect negative cable to battery.
      CAUTION
      Use extreme caution when the engine is operating. Do not stand in direct line with the fan. Do not put hands near the pulleys, belts or fan. Do not wear loose clothing.

    46.  
    47. Operate the engine with the radiator cap off. Inspect for leaks and continue operating the engine until the engine thermostat opens. Add coolant, if required.
    48.  

     
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