Remove/install cylinder head

AR01.30-P-5800PR

Remove/install cylinder head

16.10.09

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove air filter housing (1).

AR09.10-P-1150PR

2

Remove engine covers above (2)

3

Remove cylinder head cover (3) with vent hose

AR01.20-P-5014PK

4

Remove air shroud (4)

 Installation: Inspect O-ring for air scoop; replace if necessary.

5

Remove vacuum line (5) on intake manifold connection (6)

 Removal: To do this, press the two clamps on the catch together and pull out the vacuum line.

6

Remove exhaust gas recirculation valve (7)

7

Remove switchover valve (Y32) from bracket (8)

 Detach two vacuum lines on the switchover valve (Y32) in the process.

8

Remove bracket (8) from intake manifold

9

Remove automatic transmission oil dipstick guide tube on lifting eye

 Only with transmission 722.6.

 Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

10

Remove fuel distributor (9) with injector valves

AR07.03-P-1450GS

11

Remove intake manifold (10) at cylinder head

 Removal: Detach vacuum line for purge valve. Pull intake manifold from cylinder head and fix in place in engine compartment together with attached lines.

 Installation: Replace seals on intake manifold. Clean sealing surfaces.



*BA09.20-P-1001-01B

12

Detach crankcase breather line



Below flange connection for intake manifold/cylinder head.

AR01.30-P-5800-06GS

13

Remove lower engine compartment paneling

AR61.20-P-1105P

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

14

Drain coolant

 Drain coolant at crankcase.

AR20.00-P-1142PR



Notes on coolant

All engines

AH20.00-N-2080-01A

15

Remove front exhaust system (12) on exhaust manifold

 Installation: Install new bolts (13). Inspect rivet nuts in exhaust manifold, replace if necessary.

Replace rivet nuts in exhaust manifold.

AR49.10-P-5531-01DA



*BA49.10-P-1005-01F

16

Detach exhaust bracket (14) on transmission

 Secure exhaust system against falling down.



*BA49.10-P-1003-01F

17

Detach the heater coolant line (15)

 Push back clamp (16) until it locks in place; pull out coolant line.

 Installation: Check coolant line, replace if necessary. Replace seal of coolant line.

18

Rotate engine at crankshaft in direction of rotation until the piston of cylinder 1 is positioned at 20° after the TDC marking

 The 20° TDC marking on belt pulley/vibration damper (17) must be aligned with positioning edge (A) on the timing case cover.

The cams of the exhaust camshaft and of the inlet camshaft at cylinder 1 must be pointing up at an angle.

19

Remove coolant thermostat housing

AR20.10-P-2710PK

20

Remove front cover at cylinder head

AR01.30-P-5700PK

21

Marl camshaft sprocket to timing chain with a color dot

22

Remove chain tensioner (11)

AR05.10-P-7800PK

23

Remove slide rail above (18)

 Remove bolts (19).



*BA05.10-P-1003-01B

24

Remove exhaust camshaft sprocket (20)

 Removal: Counterhold bolts (21) for exhaust camshaft when loosening and tightening.



*104589010100

 Installation: Replace bolts (21).



*BA05.20-P-1001-02A

25

Unscrew camshaft bearing cap on intake camshaft (22)

 Installation: Tighten intake camshaft bearing cap evenly (risk of cracks and fracture). The camshaft bearing caps must be installed again at the same point.

*BE05.20-P-1001-03A



Marking of camshaft bearing caps

Engine 111

AH05.20-N-6992-01A



*BA05.20-P-1004-02A

26

Remove timing chain (23) from intake camshaft sprocket

27

Remove inlet camshaft (22)

 Installation:

Oil compensation elements and camshaft bearing points.

The cams of the inlet camshaft must be pointing up at an angle at cylinder 1 after inserting the inlet camshaft (risk of fracturing).

*BE05.20-P-1002-03A

If necessary check camshaft end play in fit bearing.

*BE05.20-P-1003-03A

Set basic position of exhaust/intake camshaft.

AR05.20-P-6020GS

28

Pull out slide rail bolt for left slide rail

 Installation: Coat slide rail pins with sealant.

AR01.30-P-5800-04GS

Omnifit FD 3041 sealant.

*BR00.45-Z-1012-01A

29

Remove bolts (24) of cylinder head to timing case cover

 Installation: Replace bolts and wet bolt head contact surface slightly with engine oil.



*BA01.40-P-1002-01G

30

Slacken cylinder head bolts in stages and remove

 Slacken cylinder head bolts in the reverse order of the tightening procedure only once engine has cooled down.

 Installation: Observe tightening procedure of cylinder head bolts.

AR01.30-P-5800-01GS

Wet cylinder head bolts on thread and head contact surface slightly with engine oil.

 It is not necessary to retighten the cylinder head bolts.



*BA01.30-P-1002-01B

31

Check cylinder head bolts



AR01.30-P-5800-03HA

32

Remove cylinder head

 Installation: Clean contact surfaces of cylinder head and crankcase. Replace cylinder head gasket. Pay attention to the guide rails when fitting on the cylinder head. Pay attention to dowel sleeves (25) for locating the cylinder head.

33

Inspect contact surfaces of cylinder head and of crankcase for cracks and flatness

 If necessary, face-grind cylinder head contact surface.

AR01.30-P-7162GS

34

Blow out threaded holes of cylinder head bolts in crankcase with compressed air

35

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

36

Check for leaks with engine running

37

Bleed cooling system

 Warm up engine to operating temperature and set temperature control of heater to warm.

38

Inspecting cooling system for leaks

 Warm up engine to operating temperature.

AR20.00-P-1010P

39

Read out fault memory and erase

 STAR diagnosis!

Number

Designation

Engine 111

BE05.20-P-1001-03A

Camshaft bearing diameter

Standard size

mm

28.00 to 28.02

Repair stage

mm

28.50 to 28.52

BE05.20-P-1002-03A

Diameter of camshaft bearing journal

Standard size

mm

27.95 to 27.96

Repair stage

mm

28.45 to 28.46

BE05.20-P-1003-03A

Axial clearance of camshaft in fit bearing

mm

0.05 to 0.15

Number

Designation

Engine 111

BA01.30-P-1002-01B

Bolt, cylinder head

M12

Stage 1

Nm

55

Stage 2

°

90

Stage 3

°

90

See picture

AR01.30-P-5800-01A

Number

Designation

Engine
111

BA01.40-P-1002-01G

Bolt, cylinder head to timing case cover

Stage 1

Nm

18

Stage 2

°

90

Number

Designation

Engine
111

BA05.10-P-1003-01B

Bolts for top of guide rail

Nm

10

Number

Designation

Engine
111

BA05.20-P-1001-02A

Bolt for camshaft sprocket/flange shaft

Stage 1

Nm

20

Stage 2

°

60

BA05.20-P-1004-02A

Bolt for camshaft bearing cap

Nm

21

Number

Designation

Engine 111

BA09.20-P-1001-01B

Bolts and nuts, intake manifold to cylinder head

Nm

20

Number

Designation

Engine 111 in model 203

BA49.10-P-1003-01F

Bolt of exhaust bracket to transmission

Nm

20

BA49.10-P-1005-01F

Bolt, flange connection to exhaust pipes or exhaust manifold

Nm

20

Number

Designation

Order number

BR00.45-Z-1012-01A

Omnifit FD 3041 sealant

A 002 989 47 20 10