Mercedes-Benz Truck 2000-05

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     

  4.  
  5. Drain and recycle the engine coolant.

    Engine cooling fan and clutch
     
    Fan shroud
     

  6.  


NOTE
The fan clutch is equipped with right-hand thread.

  1. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation.

    Engine cover
     
    Air cleaner housing, resonance pipe and body
     

  2.  
  3. Properly relieve the fuel system pressure.

    Fuel line
     
    Ignition coils
     
    Cylinder head covers
     

  4.  


NOTE
The intake manifold system must not be disassembled.



Intake manifold
 
Vacuum switchover valve
 
Camshaft Position (CMP) sensor
 

  1. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner.

    Serpentine belt
     
    Heater hose at left cylinder head
     
    Driver side fender liner
     
    Exhaust support bracket
     
    Power steering pump and position it aside leaving the hoses attached
     
    Exhaust system from the exhaust manifolds
     

  2.  
  3. Rotate the engine clockwise to position the crankshaft 40 degrees after top dead center.
  4.  


WARNING
The engine must not be rotated backward.

  1. Lock the camshafts using the Camshaft Locking tools 112 589 00 32 00 and 112 589 01 32 00.
  2.  
  3. Remove or disconnect the following:

    Generator, then the timing chain tensioner
     
    Oil filter housing and heat exchanger
     
    Camshaft gears and attach them to the chain with a cable tie
     
    Camshaft bearing bridges
     
    Timing case-to-cylinder head bolts
     

  4.  
  5. Loosen and remove the cylinder head bolts in stages following the illustrated sequence.

    Cylinder head off the engine block
     
    All gasket material from the sealing surfaces of the cylinder head and engine block. Be careful not to gouge or scratch the surface of the aluminum head. Be sure the cylinder head locating dowels are positioned in the engine block. Clean and dry the head bolt holes using compressed air.
     

  6.  
  7. Measure the length of the cylinder head bolt shafts, new bolt length is 5.57 inches (141.5mm) and the maximum permissible length is 5.69 inches (144.5mm). Replace bolts that measure greater than the maximum permissible length.
  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head accessory components-3.2 and 3.7L engines shown; 4.3L and 5.0L engines similar



    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head removal-3.2 and 3.7L engines shown; 4.3L and 5.0L engines similar



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.2 and 3.7L engines



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-4.3L and 5.0L engines


To install:



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.2 and 3.7L engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-4.3L and 5.0L engines

  1. Clean the head bolt threads, then apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install the cylinder head to the engine block and tighten the head bolts according to sequence as follows:
    1. Step 1. 96 inch lbs. (10 Nm).
    2.  
    3. Step 2. 22 ft. lbs. (30 Nm).
    4.  
    5. Step 3. 90 degrees.
    6.  
    7. Step 4. additional 90 degrees.
    8.  

  4.  
  5. Install or connect the following:

    Timing case-to-cylinder head bolts and tighten to 15 ft. lbs. (20 Nm)
     
    Camshaft bearing bridges
     
    Camshaft gear and tighten the mounting bolt to 37 ft. lbs. (50 Nm) plus an additional 90 degrees. Check the basic camshaft position and adjust if necessary.
     
    Timing chain tensioner with a new gasket and tighten to 59 ft. lbs. (80 Nm)
     
    Generator
     

  6.  
  7. Remove the camshaft locking plates.

    Exhaust system to the manifolds and tighten the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Heater hose to the cylinder head
     
    Power steering pump
     
    Serpentine belt and remove the locking pin
     
    CMP sensor
     
    Vacuum switchover valve
     
    Intake manifold
     
    Cylinder head covers and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Ignition coils and tighten the mounting bolts to 70 inch lbs. (8 Nm)
     
    Fuel pipe
     
    Air cleaner housing, resonance pipe and body
     
    Engine cover
     

  8.  
  9. Remove the guard plate from the radiator/condenser.

    Fan shroud, then the cooling fan
     

  10.  
  11. Fill the engine with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Read fault memory, encode the radio and normalize the power windows.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     

  4.  
  5. Drain and recycle the engine coolant.
    NOTE
    The fan clutch is equipped with right-hand thread.



    Engine cooling fan and clutch
     
    Fan shroud
     

  6.  
  7. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation.

    Engine cover
     
    Air cleaner housing, resonance pipe and body
     

  8.  
  9. Properly relieve the fuel system pressure.
    NOTE
    The intake manifold system must not be disassembled.



    Fuel line
     
    Ignition coils
     
    Cylinder head covers
     



    Intake manifold
     
    Vacuum switchover valve
     
    Camshaft Position (CMP) sensor
     

  10.  
  11. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner.

    Serpentine belt
     
    Power steering pump and position it aside leaving the hoses attached
     
    Heater hose at the firewall
     
    Exhaust system from the exhaust manifolds
     

  12.  
  13. Rotate the engine clockwise to position the crankshaft 40 degrees after top dead center.
    WARNING
    The engine must not be rotated backwards.

  14.  
  15. Lock the camshafts using the Camshaft Locking tools 112 589 00 32 00 and 112 589 01 32 00.
  16.  
  17. Remove or disconnect the following:

    Generator, then the timing chain tensioner
     
    Camshaft gears and attach them to the chain with a cable tie
     
    Camshaft bearing bridges
     
    Timing case-to-cylinder head bolts
     

  18.  
  19. Loosen and remove the cylinder head bolts in stages following the illustrated sequence.

    Cylinder head off the engine block
     
    All gasket material from the sealing surfaces of the cylinder head and engine block. Be careful not to gouge or scratch the surface of the aluminum head. Be sure the cylinder head locating dowels are positioned in the engine block. Clean and dry the head bolt holes using compressed air.
     

  20.  
  21. Measure the length of the cylinder head bolt shafts, new bolt length is 5.57 inches (141.5mm) and the maximum permissible length is 5.69 inches (144.5mm). Replace bolts that measure greater than the maximum permissible length.

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head accessory components-3.2L engine shown



    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head removal-3.2L engine shown



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.2L Engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-4.3L Engine

  22.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.2L Engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-4.3L Engine

  1. Clean the head bolt threads, then apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install the cylinder head to the engine block and tighten the head bolts according to sequence as follows:
    1. Step 1. 15 ft. lbs. (20 Nm).
    2.  
    3. Step 2. 37 ft. lbs. (50 Nm).
    4.  
    5. Step 3. 60-70 degrees.
    6.  
    7. Step 4. additional 60-70 degrees.
    8.  

  4.  
  5. Install or connect the following:

    Timing case-to-cylinder head bolts and tighten to 15 ft. lbs. (20 Nm)
     
    Camshaft bearing bridges
     
    Camshaft gear and tighten the mounting bolt to 37 ft. lbs. (50 Nm) plus an additional 90 degrees. Check the basic camshaft position and adjust if necessary.
     
    Timing chain tensioner with a new gasket and tighten to 59 ft. lbs. (80 Nm)
     
    Generator
     

  6.  
  7. Remove the camshaft locking plates.

    Exhaust system to the manifolds and tighten the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Heater hose to the cylinder head
     
    Power steering pump
     
    Serpentine belt and remove the locking pin
     
    CMP sensor
     
    Vacuum switchover valve
     
    Intake manifold
     
    Cylinder head covers and tighten the bolts to 88 inch lbs. (10 Nm)
     
    Ignition coils and tighten the mounting bolts to 70 inch lbs. (8 Nm)
     
    Fuel pipe
     
    Air cleaner housing, resonance pipe and body
     
    Engine cover
     

  8.  
  9. Remove the guard plate from the radiator/condenser.

    Fan shroud, then the cooling fan
     

  10.  
  11. Fill the engine with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Read fault memory, encode the radio and normalize the power windows.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     

  4.  
  5. Drain and recycle the engine coolant.
    NOTE
    The fan clutch is equipped with right-hand thread.



    Engine cooling fan and clutch
     
    Fan shroud
     

  6.  
  7. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation.

    Engine cover
     
    Air cleaner housing, resonance pipe and body
     

  8.  
  9. Properly relieve the fuel system pressure.
    NOTE
    The intake manifold system must not be disassembled.



    Fuel line
     
    Ignition coils
     
    Cylinder head covers
     



    Intake manifold
     
    Vacuum switchover valve
     
    Camshaft Position (CMP) sensor
     

  10.  
  11. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner.

    Serpentine belt
     
    Heater hose at left cylinder head
     
    Driver side fender liner
     
    Exhaust support bracket
     
    Power steering pump and position it aside leaving the hoses attached
     
    Exhaust system from the exhaust manifolds
     

  12.  
  13. Rotate the engine clockwise to position the crankshaft 40 degrees after top dead center.
    WARNING
    The engine must not be rotated backward.

  14.  
  15. Lock the camshafts using the Camshaft Locking tools 112 589 00 32 00 and 112 589 01 32 00.
  16.  
  17. Remove or disconnect the following:

    Generator, then the timing chain tensioner
     
    Oil filter housing and heat exchanger
     
    Camshaft gears and attach them to the chain with a cable tie
     
    Camshaft bearing bridges
     
    Timing case-to-cylinder head bolts
     

  18.  
  19. Loosen and remove the cylinder head bolts in stages following the illustrated sequence.

    Cylinder head off the engine block
     
    All gasket material from the sealing surfaces of the cylinder head and engine block. Be careful not to gouge or scratch the surface of the aluminum head. Be sure the cylinder head locating dowels are positioned in the engine block. Clean and dry the head bolt holes using compressed air.
     

  20.  
  21. Measure the length of the cylinder head bolt shafts, new bolt length is 5.57 inches (141.5mm) and the maximum permissible length is 5.69 inches (144.5mm). Replace bolts that measure greater than the maximum permissible length.

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head accessory components-M112 engines shown; M113 engines similar



    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head removal-M112 engines shown; M113 engines similar



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-M112 engines



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-M113 engines

  22.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-M112 engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-M113 engines

  1. Clean the head bolt threads, then apply clean engine oil to the thread and head contact surfaces.
  2.  
  3. Install the cylinder head to the engine block and tighten the head bolts according to sequence as follows:
    1. Step 1. 96 inch lbs. (10 Nm).
    2.  
    3. Step 2. 22 ft. lbs. (30 Nm).
    4.  
    5. Step 3. 90 degrees.
    6.  
    7. Step 4. additional 90 degrees.
    8.  

  4.  
  5. Install or connect the following:

    Timing case-to-cylinder head bolts and tighten to 15 ft. lbs. (20 Nm)
     
    Camshaft bearing bridges
     
    Camshaft gear and tighten the mounting bolt to 37 ft. lbs. (50 Nm) plus an additional 90 degrees. Check the basic camshaft position and adjust if necessary.
     
    Timing chain tensioner with a new gasket and tighten to 59 ft. lbs. (80 Nm)
     
    Generator
     

  6.  
  7. Remove the camshaft locking plates.

    Exhaust system to the manifolds and tighten the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Heater hose to the cylinder head
     
    Power steering pump
     
    Serpentine belt and remove the locking pin
     
    CMP sensor
     
    Vacuum switchover valve
     
    Intake manifold
     
    Cylinder head covers and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Ignition coils and tighten the mounting bolts to 70 inch lbs. (8 Nm)
     
    Fuel pipe
     
    Air cleaner housing, resonance pipe and body
     
    Engine cover
     

  8.  
  9. Remove the guard plate from the radiator/condenser.

    Fan shroud, then the cooling fan
     

  10.  
  11. Fill the engine with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Read fault memory, encode the radio and normalize the power windows.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

 
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