Remove/install cylinder head

AR01.30-P-5800A

Remove/install cylinder head

10.11.11

1.8.97

Technical modification: Bolts+washers of cylinder head to timing case cover are replaced by Torx bolts without washer

Step 25

 

Remove/install

1

Drain coolant at crankcase

AR20.00-P-1142HG

2.1

Remove coolant expansion reservoir

Model 163

3

Unbolt exhaust system at exhaust manifold

Model 163

Model 170

AR49.10-P-7000G

Model 124, 202

AR49.10-P-7000D

Model 208

AR49.10-P-7000DA

Model 210

AR49.10-P-7000BA

4.1

Unbolt bracket for exhaust manifold at transmission

Engines fitted with bracket of exhaust manifold at transmission

5

Remove cover of coolant thermostat housing

6

Unplug electrical connections at the cylinder head

AR01.30-P-5800-08A

7

Unbolt intake manifold (19), swivel to the side with lines connected

Engine 111.943/973 in model 170

Engine 111.944/975 as of 09.96 in model 202

Engine 111.975 in model 208

Engine 111.947 in model 210

(engines with plastic intake manifold)

AR09.20-P-1310GB

Engine 111.920/940/941/944/975 up to 08.96
Engine 111.960/961 (engines with aluminum intake manifold)

AR09.20-P-1310G

Engine 111.921/942/945/946/970/974/977

(engines with plastic intake manifold)

AR09.20-P-1310GA

8

Detach crankcase ventilation line

 Below flange connection of intake manifold/cylinder head

AR01.30-P-5800-06A

9.1

Disconnect plug connections of partial intake manifold preheater

ENGINE 111.940 up to 07.93

Engine 111.960 up to 08.93

AR01.30-P-5800-05A

10.1

Unbolt bracket (2)

Engine 111 with aluminum intake manifold

11

Detach coolant hose (3) at rear of cylinder head

12

Remove front cover at cylinder head

AR01.30-P-5700A

13

Unbolt dipstick guide tube (7)

14.1

Unbolt dipstick guide tube (8)

 If automatic transmission fitted

15

Position crankshaft to a 20° - 30° crank angle after ignition TDC on cylinder 1

16

Lock camshafts (75 and 78) in place with locating pins (01)



*111589031500

17

Mark camshaft sprockets and timing chain with colored marking

 Installation: Place timing chain in such a way that the color codings on the timing chain and on the camshaft sprockets lie one above the other.

18

Remove chain tensioner (14)

 Installation:

Prepare chain tensioner for installation.

AR05.10-P-7800A

19

Remove slide rail in cylinder head

AR05.10-P-8432A

20

Remove exhaust camshaft sprocket (76)



*000589011000



 Replace screw/bolts for camshaft sprocket; use only once.

*BA05.20-P-1001-02A

21.1

Remove inlet camshaft sprocket (74)

 Engines not fitted with camshaft adjuster

*000589011000



 Replace screw/bolts for camshaft sprocket; use only once.

*BA05.20-P-1001-02A

22.1

Remove inlet camshaft with camshaft adjuster

Engine fitted with camshaft adjuster

AR05.20-P-6992A

23

Screw/bolt on bracket (16) for removing cylinder head



 Unbolt 1st camshaft bearing cap and screw on bracket (16) using bearing cap bolts.

*104589004000



*BA05.20-P-1004-02A

24

Remove slide rail pins (11)



AR01.30-P-5800-04A

 Installation: Apply sealant to the slide rail pins

*BR00.45-Z-1012-01A

25

Unscrew screw/bolts (A) of cylinder head to timing case cover in chain housing


 Installation: Replace screw/bolts (A), bolts and washers for engines as of 1994 (enlarged bolt head contact surface,

 17 mm) with Torx bolts without washers.
Oil bolt head contact surface, tighten Screw/bolts to specified torque and tightening angle.

*BA01.40-P-1002-01G



*000589011000



Modified bolts (Torx bolts) for cylinder head to timing case cover

BT01.30-P-0002-01A

26

Slacken cylinder head bolts (12) in increments, unscrew



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

*617589001000

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01A


 Installation: Oil thread and bolt head contact surface of cylinder head bolts, insert, tighten in stages

*617589001000

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

*BA01.30-P-1002-01B

27

Check cylinder head bolts (12)

AR01.30-P-5800-03HA

28

Attach engine hoist to bracket (16) and to rear engine lifting eye

Load regulator

gotis://H_00.12_04.0

If necessary for model 210: Use engine supporting frame

29

Raise cylinder head with engine hoist, remove

 Installation: Inspect cylinder head gasket (88), replace.

 When fitting on cylinder head, pay attention to guide rails; tie guide rails together, if necessary.

 Pay attention to dowel sleeves (15) for locating the cylinder head.

 Engine 111.940/960 with staged front dowel pin 

Remove/install staged dowel pin

AR01.30-P-5800-10A

30

Clean contact surfaces, inspect for cracks and flatness

Face-grind cylinder head separating surface if necessary

AR01.30-P-7162A

31

Clean threaded holes

 It is important to ensure that the threaded holes are free of oil and water.

32

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

33

Check for leaks with engine running

34

Inspect cooling system for leaks

 Do not pressure-test cooling system until engine has reached operating temperature.

 As the cylinder head gasket is not watertight until the engine has reached operating temperature and the gasket has swollen.

AR20.00-P-1010HA

Number

Designation

Engine
111

BE01.30-P-1001-04B

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

102

Length (L)

mm

105

See picture

AR01.30-P-5800-03HA

Number

Designation

Engine 111

BA01.30-P-1002-01B

Screw/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

Screw/bolt, cylinder head to timing case cover

Stage 1

Nm

18

Stage 2

°

90

Number

Designation

Engine
111

BA05.20-P-1001-02A

Screw/bolt for camshaft sprocket/flange shaft

Stage 1

Nm

20

Stage 2

°

60

BA05.20-P-1004-02A

Screw/bolt for camshaft bearing cap

Nm

21

Number

Designation

Order number

BR00.45-Z-1012-01A

Sealant, Omnifit FD 3041

A 002 989 47 20 10