Remove/install cylinder head

AR01.30-P-5800RT

Remove/install cylinder head

18.02.2020

Engine

113.971 in model 251.075/175

3

Poly-V-belt

13

Intake manifold

B2/5

Hot film mass air flow sensor

6

Air intake pipe

15

Coolant line

B6/1

Camshaft Hall sensor

7

Right cylinder head cover

16

Camshaft sprockets

G2

Alternator

9

Left cylinder head cover

17

Camshaft bearing bridges

T1/1-T1/4

Cylinder 1 to 4 ignition coil

12

Chain tensioner

18

Oil filter housing with oil water heat exchanger

T1/5-T1/8

Cylinder 5 to 8 ignition coil

20

Bolts

23

Right cylinder head

25

Right cylinder head seal

21

Cylinder head bolts

24

Left cylinder head seal

26

Fitting sleeves

22

Left cylinder head

 

Remove/install

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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

 Danger

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.

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

AS47.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Danger

Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground line of battery

AR54.10-P-0003RT

Topical note

Notes on battery

AH54.10-P-0001-01A


Insulate clamping device for ground line.
This is to prevent inadvertent contact with the battery ground point.

 Vehicles with Keyless Go, Code 889:
Switch engine off, remove Keyless-Go cards from vehicle and store outside of transmission range.

2

Remove lower engine compartment paneling

AR61.20-P-1105RT

3

Drain coolant at radiator

AR20.00-P-1142GZ

4

Remove partition wall between wheel wells

AR62.30-P-2400RT

5

Remove engine cover

AR01.10-P-2405RT

6

Remove hot film mass air flow sensor (B2/5) with air intake pipe

AR07.07-P-1454RT

7

Relieve fuel pressure with pressure hose via service valve

AR07.03-P-1460-01GZ

 Pressure hose

*119589046300

8

Detach fuel feed line from the fuel distributor

 Collect escaping fuel with an absorbent rag.

 Fuel feed line to fuel distributor

*BA07.52-P-1001-01A

9

Remove ignition coil for cylinder 1 to 4 (T1/1-T1/4) and ignition coil for cylinder 5 to 8 (T1/5-T1/8)

AR15.12-P-2003RT

10

Remove the right cylinder head cover (7) and the left cylinder head cover (9)

AR01.20-P-5014RT

11

Remove air pump

AR14.30-P-7251RT

12

Remove intake manifold (13)

AR09.20-P-1310RT

 Installation:
In vehicles with engine damage, the intake manifold (13) must undergo a visual inspection for chippings before assembly.
Any chippings must be removed. Otherwise, engine damage will occur again.

13

Remove camshaft Hall sensor (B6/1)

AR15.10-P-2000RT

 Only when removing the right cylinder head (23).

14

Remove poly-V-belt (3)

AR13.22-P-1202RT

 Only when removing the left cylinder head (22).

15

Remove coolant line (15) from left cylinder head (22) on firewall

 Engage the safety spring in the grid marking with the screwdriver and remove the coolant line.

 Installation: Replace O-ring. Before installing the coolant line, bring the safety spring into basic position.

16

Disconnect exhaust system from exhaust manifold

 Installation:
In vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed prior to installation.
Otherwise, they could cause damage to the catalytic converter system.

 Flange connection of exhaust manifold and front exhaust pipes

*BA14.10-P-1002-01B

17

Rotate engine at crankshaft center bolt in direction of engine rotation to a 40° crankshaft angle downstream of after ignition TDC on the first cylinder

 Do not reverse crank the engine.

 The groove on the camshaft must point in the direction of "Inner-V".

18

Lock the camshaft with the fixing plate

 Right plate: 

 Left plate: 

 Fixing plate

*112589003200

 Arresting plate

*112589013200

19

Unscrew the screws in the oil filter housing with oil water heat exchanger (18)

AR18.30-P-3481RT

 Only when removing the left cylinder head (22).

20

Remove chain tensioner (12)

AR05.10-P-7800RT

 Place the alternator (G2) with connected lines to one side.

21

Detach camshaft sprockets (16) from the camshaft

Check engine valve timing

AR05.10-P-6858RT

Set basic position of camshafts

AR05.20-P-6020RT


When the camshaft sprockets (16) have been removed, the engine must no longer spin.
Otherwise, the timing chain can tilt and this can lead to damage.

 Right camshaft sprocket:
Tie the timing chain to the camshaft sprocket with the cable tie.

 Left camshaft sprocket:
mark the camshaft sprocket to the timing chain and remove the camshaft sprocket.

 Installation: Check basic position of camshafts.

 Camshaft sprocket bolt

*BA05.20-P-1001-01B

 Open-end wrench

*112589000100

 Insertion tool

*112589010300

 Torque wrench

*001589722100

after test, if necessary



Set basic position of camshaft

22

Remove camshaft bearing bridges (17)

AR05.20-P-7103RT

23

Unscrew screws/bolts (20)

 Screw/bolt, cylinder head to timing case cover

*BA01.40-P-1002-01C

24

Loosen cylinder head bolts (21) in stages and remove them

Slackening diagram for cylinder head bolts

AR01.30-P-5800-09B

Tightening specifications for cylinder head bolts

AR01.30-P-5800-07B


Release cylinder head bolts according to loosening procedure on a cooled down engine:
Otherwise, the additional torque influence will cause the elastic area of the cylinder head bolts to exceeded.

 Installation:
Pay attention to tightening procedure and tightening specifications for the cylinder head bolts.
Distortion of the cylinder head will occur otherwise. Oil cylinder head bolts at thread and bolt head contact surface.

 Bolt, cylinder head to crankcase

*BA01.30-P-1001-01D

 Screwdriver bit

*000589031000

25

Remove cylinder head

Topical note

Information on applying sealant to cylinder head gasket

AH01.30-P-1000-04RX

Information on cylinder head contact surface

AH01.30-P-1000-05A

Notes on assigning the cylinder head gaskets

AH01.30-P-1000-06V

 Installation: Pay attention to fitting sleeves (26) for fitting the cylinder head.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A



Clean

26

Clean the threaded holes and sealing surfaces of the cylinder crankcase and cylinder heads

Remove sealant

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces will be damaged otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A



Check

27

Check cylinder head screws (21)

AR01.30-P-5800-03B

Cylinder head bolt

*BE01.30-P-1001-04B

28

Check cylinder crankcase and cylinder head for cracks, shrink holes and flatness

 Sealing surfaces of the cylinder crankcase and cylinder head are provided with an 0.8 mm thick silicone layer during series production. Silicone sealant is applied in the gasket area when carrying out repairs only if shrink holes are present. The sealant must be applied within 10 minutes.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

29

Install in the reverse order

30

Check cooling system for leaktightness

AR20.00-P-1010GZ

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

31

Carry out engine test run and check engine for leaktightness while it is running


If there is a fluid loss, determine and eliminate the cause.
Malfunctions, engine and environmental damage can occur otherwise.

32

Read out fault memory and clear



Connect Star Diagnosis

AD00.00-P-2000-04A

 Stored faults entries which may have been caused by disconnecting lines or by a simulation must be erased in the fault memory after completing the work.

Cylinder head/cylinder head bolts

Number

Designation

Engine 113

BE01.30-P-1001-04B

Cylinder head bolt

Thread diameter

M

11

Length (L) when new

mm

141,5

Length (L)

mm

144,5

For picture, see

AR01.30-P-5800-03B

 Cylinder head

Number

Designation

Engine 113.940/941/942/943/944/948/960/961/962/963/965/966/967/968/969/971/980/981/982/984/986

BA01.30-P-1001-01D

Bolt, cylinder head to crankcase

Stage 1

Nm

10

Stage 2

Nm

30

Stage 3

°

90

Stage 4

°

90

 Cylinder crankcase, timing case cover, end cover

Number

Designation

Engine 113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981/982/984/986/992/995

BA01.40-P-1002-01C

Screw/bolt, cylinder head to timing case cover

Nm

20

 Camshaft

Number

Designation

ENGINE 113.940 /941/942/943/944 /948/961/962/963 /964/965/966/967 /968/969/971/980 /981/982/984/986 /992/995

BA05.20-P-1001-01B

Camshaft sprocket bolt

M1245

Stage 1

Nm

50

Stage 2

°

90

 Fuel distributor

Number

Designation

Engine 113.940 /941/942/943/944 /948/960/961/962 /963/964/965/966 /967/968/969/971 /980/981/982/984 /986/988

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

 Exhaust manifold

Number

Designation

Engine 113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981/982/984/986/992/993/995

BA14.10-P-1002-01B

Flange connection of exhaust manifold and front exhaust pipes

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09