P01.30-2234-12
Shown on engine 134.9
1 Cylinder head
2 Coolant hose
3 Coolant hose
4 Coolant pipe
P05.10-2288-11
Shown on engine 134.9
14 Chain tensioner
15 Screw/bolt
16 Tensioning rail
17 Screw/bolt
18 Slide rail
19 Timing chain
P01.30-2227-06
Shown on engine 135.9
1 Cylinder head
5 Cylinder crankcase
6 Cylinder head gasket
7 Cylinder head bolt
8 Washer
9 Screw/bolt
10 Bracket
11 Intake manifold
12 Screw/bolt
13 Lifting eye
| Removing | ||
1 | Remove engine with transmission | ||
2 | Disconnect transmission from timing case | See: | |
Remove/install starter | |||
3 | Install removed engine on assembly stand | ||
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Engine assembly stand | |||
Workshop crane/engine crane | |||
4 | Turn engine to ignition TDC for cylinder 1 | See: | |
Check basic position of camshafts | |||
5 | Remove timing case cover | ||
6 | Remove camshafts | Also remove camshaft sprocket on exhaust camshaft. | |
7 | Take off timing chain (19) | ||
8 | Remove valve tappet | ||
9 | Remove bolt (15) and tensioning rail (16) | ||
10 | Remove screw/bolt (17) and slide rail (18) | ||
11 | Remove coolant hoses (2, 3) from cylinder head (1) and from coolant pipe (4) | ||
12 | Unscrew bolt (9) from bracket (10) | Bracket (10) remains on cylinder head (1). | |
13 | Remove screw/bolt (12) and detach suspension eyelet (13) from cylinder head (1) | ||
14 | Remove adjustable camshaft timing solenoid | ||
15 | Gradually unscrew cylinder head bolts (7) and remove with washers (8) | In order to avoid stresses in cylinder head (1) and loosen cylinder head bolts (7) in the reverse order of tightening instructions. See: | |
Tightening specifications for cylinder head bolts | |||
16 | Remove cylinder head (1) from crankcase (5) | ||
17 | Take cylinder head gasket (6) off crankcase (5) | ||
| Checking | ||
18 | Clean sealing surfaces on the cylinder head (1) and crankcase (5) and check for visible damage | ||
19 | Clean separating surface on cylinder head (1) and check for damage and flatness | An uneven sealing surface of cylinder head (1) can lead to leaks in the area of cylinder head gasket (6). | |
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20 | Clean separating surface on crankcase (5) and check for damage and flatness | An uneven sealing surface of crankcase (5) can lead to leaks in the area of cylinder head gasket (6). | |
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21 | Check cylinder head bolts (7) | Replace overlong cylinder head bolts (7). | |
| Install | ||
22 | Check tapped holes for cylinder head bolts (7) in crankcase (5) for contamination; clean if necessary | ||
23 | Place cylinder head gasket (6) on crankcase (5) | Replace cylinder head gasket (6). Pay attention to installation position of cylinder head gasket (6). Place cylinder head gasket (6) into the guide pins (arrows). | |
24 | Place cylinder head (1) on crankcase (5) | When replacing the cylinder head (1), the intake manifold (11) must be modified. When positioning the cylinder head (1), the guide pins (arrows) on crankcase (5) must engage with guide bores of the cylinder head (1). | |
25 | Insert cylinder head bolts (7) with washers (8) into the cylinder head (1) and tighten in stages | Tighten cylinder head bolts (7) according to the sequence of the tightening instructions. | |
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26 | Install solenoid for camshaft control | ||
27 | Attach lifting eye (13) to cylinder head (1) and tighten screw/bolt (12) | ||
28 | Tighten bracket (10) with bolt (9) | The bracket (10) must lie flat on crankcase (5) when screwing in bolt (9). If the bracket (10) is not flat on the crankcase (5), loosen bracket (10) and reposition. | |
29 | Attach coolant hoses (2, 3) to cylinder head (1) and to coolant pipe (4) | Make sure that coolant hoses (2, 3) are seated correctly. | |
30 | Insert valve tappet in cylinder head (1) | See: | |
Remove/install valve tappets | |||
31 | Install camshafts | Do not install exhaust camshaft camshaft sprocket. | |
32 | Position slide rail (18) and tighten screw/bolt (17) | | |
33 | Position tensioning rail (16) and tighten bolt (15) | | |
34 | Install timing chain (19) with exhaust camshaft camshaft sprocket | See: | |
Set basic position of camshafts | |||
35 | Install timing case cover | ||
36 | Remove engine from assembly stand | ||
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Engine assembly stand for cars | |||
Boom crane | |||
37 | Attach starter to transmission | See: | |
Remove/install starter | |||
38 | Install engine with transmission |
Check values for cylinder head
Number | Designation | Engine 134.910/911 | Engine 135.930/950 | ||
BE01.30-P-1001-02F | Permissible variation of flatness of lower separating surface | over the entire length | mm | 0.03 to 0.2 | 0.03 to 0.2 |
Cylinder head/cylinder head bolts
Number | Designation | Engine 134.910/911 | Engine 135.930/950 | ||
BE01.30-P-1001-04F | Cylinder head bolt | Thread diameter | M | 9 | 9 |
Length (L) when new | mm | 143.5 | 143.5 | ||
Max. length (L) | mm | 146.2 | 146.2 | ||
See picture | - | - | |||
Check values of crankcase
Number | Designation | Engine 134.910/911 | Engine 135.930/950 | ||
BE01.40-P-1001-02I | Crankcase flatness of separating surface | over the entire length | mm | 0.05 to 0.1 | 0.05 to 0.1 |
Cylinder head
Number | Designation | Engine | Engine | Engine | Engine | ||
BA01.30-P-1001-01N | Torx bolt connecting cylinder head to crankcase | Stage 1 | Nm | 25 | 25 | 25 | 25 |
Stage 2 | ° | 90 | 90 | 90 | 90 | ||
Stage 3 | ° | 90 | 90 | 90 | 90 | ||
Timing chain drive
Number | Designation | Engine | Engine | Engine | Engine | ||
BA05.10-P-1001-01I | Bolt, timing chain guide rail to crankcase | Nm | 10 | 10 | 10 | 10 | |
BA05.10-P-1002-01I | Bolt, timing chain tensioning rail to cylinder head | Nm | 24 | 24 | 24 | 24 | |
Complete manual transmission
Number | Designation | Trans-mission 717.4 | ||
BA26.10-P-1001-01D | Bolt, transmission to engine | Nm | 23 | |
454 589 02 62 00
Engine lifting fixture
Support fixture
454 589 00 62 00