Remove/install cylinder head · ar0130d5800c · Mercedes-Benz WIS

AR01.30-D-5800C

Remove/install cylinder head

14.12.09

ENGINES 111.979 in MODEL 901.0, 902.0, 903.0, 904.0

ENGINES 111.984 in MODEL 901.6, 902.6, 903.6, 904.6

D01.30-1014-06

1 Heat shield

2 Cylinder head

3 Cylinder head bolt

4 Screw

5 Camshaft sprocket outlet

6 Camshaft sprocket inlet

7 Oil dipstick guide tube

8 Cylinder head gasket

The picture shows engine 111.979 without camshaft adjuster. The work procedure described below also applies for engine 111.984 with camshaft adjuster.

 	Remove/install
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
1	Drain coolant		AP20.00-D-2080A
2	Remove viscous fan clutch		AR20.40-D-5660C
3	Remove cylinder head cover		AR01.20-D-5014C
4	Remove front cover at cylinder head		AR01.30-D-5700C
5	Remove guide rail in cylinder head		AR05.10-D-8432C
6	Arrest camshaft		AR05.20-D-6992-07C
			*111589031500
7	Mark timing chain and camshaft sprocket in relation to one another with colored marking	 Assembly aid
8	Remove chain tensioner		AR05.10-D-7800C
		 Installation:	AR05.10-D-7800-02C
9	Remove camshaft sprockets (5 and 6)	Engine 111.979	AR05.20-D-6992-08C
			*BA05.20-N-1001-01A
			*000589011000
10	Remove camshaft sprocket from exhaust camshaft	Engine 111.984	AR05.20-D-7201-03A
		 Installation:	AR05.20-D-7201-04A
			*BA05.20-N-1001-01A
			*000589011000
11	Remove camshaft adjuster from intake camshaft	Engine 111.984	AR05.20-D-7201-01A
		 Installation:	AR05.20-D-7201-02A
			*BA05.20-N-1001-01A
			*BA05.20-N-1003-01A
			*BA05.20-N-1004-01A
			*104589010100
			*111589014000
			*000589011000
12	Pull out guide rail pins at cylinder head		AR01.30-D-5800-04C
			*605589003300
13	Detach vacuum lines at intake manifold	Engine 111.979	AR09.20-D-1310-06C
		Engine 111.984	AR09.20-D-1310-06B
			*BA09.20-N-1004-02A
14	Detach throttle control cable	Engine 111.979	AR30.10-D-3070-02C
15	Unhook control pressure cable	Engine 111.979 with automatic transmission	AR27.60-D-0500-07C
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
16	Separate fuel lines	Engine 111.979	AR47.25-D-1000-01C
		Engine 111.984	AR47.25-D-1000-01D
17	Remove supporting strut for power steering pump from power steering pump and intake manifold
18	Remove all lines and hoses fastened to cylinder head or intake manifold and obstructing removal
19	Remove air shutoff valve on cylinder head	Engine 111.984	AR14.30-D-7200-01A
20	Detach exhaust system at exhaust manifold		AR49.10-D-7140-03C
			*BA49.10-N-1001-01A
21	Remove heat shield (1)
22	Replace dipstick guide tube (7) for automatic transmission at cylinder head	Engine 111.979 with automatic transmission	AR27.00-D-0102-01C
23	Unscrew bolts (4) on timing case cover	  4 in total	*BA01.30-N-1003-01A
24	Loosen and unscrew cylinder head bolts (3) according to loosening procedure		AR01.30-S-5800-01A
			*BA01.30-N-1002-01A
			*BA01.30-N-1003-01A
25	Remove cylinder head (2) from cylinder crankcase together with cylinder head gasket (8)		AR01.30-D-5800-11C
26	Check cylinder head bolts (3), replace if necessary.		AR01.30-S-5800-03A
			*BE01.30-N-1001-01F
27	Clean sealing surfaces on cylinder head and cylinder crankcase to remove gaskets remnants
28	Blow out threaded holes for cylinder head bolts with compressed air	Cover compressed air gun and holes with rag to prevent oil splashing.
29	Install in the reverse order
30	Inspecting cooling system for leaks		AR20.00-D-1010C
31	Program the control unit version	Engine 111.979  Switch on ignition for this step, do not depress accelerator.

Check values for cylinder head bolts

Number	Designation			Engine 111.948/ 978/979/ 984


BE01.30-N-1001-01F	Cylinder head bolt	Thread diameter	M	12
		Length (L) when new	mm	102
		Length (L)	mm	105
		See picture		-

 Cylinder head

Number	Designation				Engine 111.979/ 984


BA01.30-N-1002-01A	Cylinder head on crankcase	M12	Stage 1	Nm	55
			Stage 2	°	90
			Stage 3	°	90
BA01.30-N-1003-01A	Cylinder head on timing case cover	M8		Nm	21

Camshaft

Number	Designation			Engine 111.979	Engine 111.984


BA05.20-N-1001-01A	Camshaft sprocket/flange shaft on camshaft	Stage 1	Nm	20	20
		Stage 2	°	60	60
BA05.20-N-1003-01A	Armature on camshaft adjuster control plunger	Stage 1	Nm	-	5
		Stage 2	°	-	90
BA05.20-N-1004-01A	Nut, camshaft adjuster cover		Nm	-	65

 Intake manifold, intake manifold preheater

Number	Designation		Engine 111.979/ 984


BA09.20-N-1004-02A	Vacuum line to vacuum connection of intake manifold	Nm	30

Exhaust system

Number	Designation		Engine 111.979/ 984


BA49.10-N-1001-01A	Flange connection for front exhaust system - exhaust manifold	Nm	23

104 589 01 01 00

Pressure nut

Open-end wrench, double

Torx bit set

Retaining pins

000 589 01 10 00

111 589 01 40 00

111 589 03 15 00

605 589 00 33 00

Puller

Referenced documents

ap2000d2080a Replace coolant
ar0120d5014c Removing/installing cylinder head cover
ar0130d5700c Remove/install front cover on cylinder head
ar0130d580004c Removing slide rail bolts on cylinder head
ar0130d580011c Removing, fitting on cylinder head at crankcase
ar0130s580001a Tightening procedure for cylinder head bolts
ar0130s580003a Checking cylinder head bolts
ar0510d780002c Installing chain tensioner
ar0510d7800c Removing, installing chain tensioner
ar0510d8432c Removing and installing slide rail in cylinder head
ar0520d699207c Locating camshafts
ar0520d699208c Removing and fitting camshaft sprockets
ar0520d720101a Removing camshaft adjuster from inlet camshaft
ar0520d720102a Fitting camshaft adjuster to inlet camshaft
ar0520d720103a Detaching camshaft sprocket from exhaust camshaft
ar0520d720104a Attaching camshaft sprocket to exhaust camshaft
ar0920d131006b Removing and installing vacuum lines on intake manifold
ar0920d131006c Removing and installing vacuum lines on intake manifold
ar1430d720001a Detaching air shutoff valve at cylinder head
ar2000d1010c Inspect cooling system for leaks
ar2040d5660c Remove/install viscous fan clutch
ar2700d010201c Detaching and attaching dipstick guide tube for automatic transmission at cylinder head
ar2760d050007c Detaching and attaching control pressure cable
ar3010d307002c Disconnecting and connecting the regulation cable
ar4725d100001c Disconnecting and connecting fuel lines at engine
ar4725d100001d Disconnecting and connecting fuel lines at engine
ar4910d714003c Detaching and attaching exhaust system at exhaust manifold
as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.
as4700z000101a Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.