Remove/install cylinder head (6 cyl.) RA010A1044150X(01-4150)

Operation no. of operation texts and work units or standard texts and flat rates:

01-5800 

1. Models 124, 129 with engine 104.98 
   Fig 1: Identifying Cylinder Head Remove/Install Components - Models 124, 129 With Engine 104.98

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2. Model 140 
   Fig 2: Identifying Cylinder Head Remove/Install Components - Model 140

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   Ground cable at battery	disconnect, connect, encode radio, model 140 normalize power windows.
   Coolant	drain, pour in
   Piston of cylinder 1	position to ignition TDC (step 2).
   Front cover at top	remove, install 01-2120 .
   Timing chain with camshaft sprocket	mark (step 4).
   Pin (41) of guide rail	pull off, insert (step 5).
   Engine 104.98:	remove guide sprocket (2) (left-hand thread), install (35 Nm, step 6).
   Armature (3) at camshaft adjuster	remove, install.
   Timing chain on camshaft sprockets	take off, fit on.
   Cable of position sensor at right wheelhouse	take off, fit on (step 12).
   Engine 104.98:	take off engine wiring harness, fit on (step 10).
   Tempomat cruise control linkage	disconnect, connect.
   Engine 104.99:	take off engine wiring harness, fit on (step 12).
   Vacuum lines at intake manifold	take off, fit on (step 13).
   Exhaust system at exhaust manifold	unbolt, bolt on.
   Engine 104.98:	take off air injection pipe (5) at cylinder head, fit on (step 15), replace seal (5a).
   Engine 104.99:	detach hose at non-return valve (5b) of air injection pipe, fit on (step 16).
   Bracket of dipstick guide tube (6a) and intake manifold support (6)	unbolt, bolt on (step 17).
   Line of crankcase air admission, combination support	take off, fit on (step 18).
   Fuel filler cap (pressure)	open, close (step 19).
   Engine 104.98:	disconnect fuel pipes at fuel distributor, connect (step 19).
   Engine 104.99:	disconnect fuel pipes at left wheelhouse, connect (step 19).
   If automatic transmission fitted:	unbolt dipstick guide tube at cylinder head, bolt on (step 20).
   Bowden cable (accelerator control)	take off, fit on (step 21).
   Control pressure cable	take off, fit on (step 23).
   Coolant hoses and heating water return line (8)	take off, fit on (step 24). Not model 140.
   Cylinder head bolts (9)	slacken (step 25).
   Cylinder head (10)	take off together with intake manifold and exhaust manifold (step 26).
   Cylinder head gasket (11)	replace (step 28). The cylinder head gasket is not watertight until the engine has reached operating temperature, in other words, until a swelling operation has taken place. For this reason, the cooling system must not be pressure-tested until after the engine has reached operating temperature.
   Camshafts	position, secure (step 29).
   Piston of cylinder 1	position to TDC (step 30).
   Cylinder head bolts (9)	examine (01-4050) .
   Cylinder head (10)	install, tighten (steps 31, 33, 34).
   Timing chain	fit on (step 35).

   TIGHTENING TORQUE SPECIFICATION OR TIGHTENING ANGLE
   
   

   Bolts for cylinder head cover	10
   Bolts of camshaft bearing caps	21

   1. Bolt head surface and thread oiled

   Special tools 

   Fig 3: Identifying Special Tool 116 589 01 34 00

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   Fig 4: Identifying Special Tool 116 589 20 33 00

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   Fig 5: Identifying Special Tool 104 589 00 40 00

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   Fig 6: Identifying Special Tool 617 589 00 10 00

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   Fig 7: Identifying Special Tool 001 589 72 21 00

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   Fig 8: Identifying Special Tool 001 589 65 09 00

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   NOTE: Take off cylinder head together with camshafts, intake manifold and exhaust manifold once engine has cooled down.

   Seal secondary air injection hole on side right at cylinder heads for engines without secondary air injection hole with end cover part no. 104 016 00 33.

   Removing, installing 

   1. Drain coolant at crankcase (20-0100) . Disconnect coolant and heating hoses at cylinder head.
   2. Position piston of cylinder 1 to ignition TDC.
   3. Remove front cover at top 01-2120 .
      Fig 9: [Identifying Coolant And Heating Hose]

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   4. Mark position of camshaft sprockets to timing chain. To do this, apply colored markings (arrows.)
      Fig 10: Identifying Colored Marking On Camshaft Sprockets

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   5. Pull off pin (1) for guide rail or friction rail with impact extractor 116 589 20 33 00 and threaded bolt 116 589 01 34 00.

      Installation note 

      The thread in the pin (1) must be located at the front (in direction of travel) when installed.

      Fig 11: Identifying Guide Rail Pin

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      Fig 12: [Installing Guide Rail Pin]

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      Engine 104.98 

   6. Unbolt guide sprocket (1) (left-hand thread) and take off together with bearing body (2).
   7. Unbolt armature at camshaft adjuster.
      Fig 13: Identifying Guide Sprocket And Bearing Body

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   8. Take timing chain off camshaft sprockets.
   9. Unplug position sensor at right wheelhouse.

      Installation note 

      The connector must be plugged in watertight.

      Engine 104.99 

   10. Take off engine wiring harness; to do this, slacken all the cable ties of the wiring harness and unplug all the connectors.
   11. Disconnect cruise control linkage.

       Engine 104.99 

   12. Unplug connector at engine separation point (X26/17).

       Unplug connector of electronic accelerator actuator (M16/1x1), press ratchet (arrow), connector turns through 90° by means of a spiral spring.

       Remove engine wiring harness from cable duct.

       Fig 14: Identifying Engine Separation Point And Electronic Accelerator Actuator

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   13. Detach vacuum pipes at intake manifold (arrow), fit on.
       Fig 15: Locating Vacuum Pipes

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   14. Unscrew bolts for exhaust system at flange of exhaust manifold.
   15. Detach secondary air injection pipe (1) at the cylinder head, fit on. Replace seal.
       Fig 16: Identifying Secondary Air Injection Pipe

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   16. Detach hose at non-return valve of secondary air injection pipe (arrow), unbolt bracket (1).
       Fig 17: Locating Hose At Non-Return Valve Of Secondary Air Injection Pipe

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   17. Unbolt bracket of dipstick guide tube and intake manifold support (arrows).

       Note regarding model 140 

       Remove dipstick guide tube.

       Fig 18: Locating Intake Manifold Support

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   18. Detach pipe (43) of crankcase air admission at combination support (17).
       Fig 19: Identifying Crankcase Air Admission Pipe And Combination Support

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   19. Briefly open fuel filler cap to release pressure in fuel tank.

       Unscrew fuel pipes (arrows). Counter-hold the connection fitting (1) when slackening the fuel pipe.

       Fig 20: Locating Fuel Pipes

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       Fig 21: Identifying Connection Fitting

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   20. If automatic transmission fitted, unbolt dipstick guide tube at rear of cylinder head (arrow).
       Fig 22: Locating Dipstick Guide Tube Bolt

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   21. Detach Bowden cable (30) from the accelerator control lever (9). Compress plastic clip (28) and pull out Bowden cable.

       Installation note 

       Adjust Bowden cable (30-1010 ).

   22. Detach control pressure cable (4), compress plastic clip (5) and guide plastic clip with linkage through the bracket.
       Fig 23: Identifying Bowden Cable, Accelerator Control Lever, Plastic Clip And Control Pressure Cable

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   Fig 24: Identifying Bowden Cable, Plastic Clip And Control Pressure Cable

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   1. 24 Slacken hose straps at the coolant hose to the coolant pump. Remove heating water return pipe.
   2. 25 When engine cold, slacken cylinder head bolts in stages in the reverse order of the tightening diagram, beginning with 14.
      Fig 25: Identifying Removal Sequence Of Cylinder Head Bolts

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   3. 26 Remove camshaft bearing caps 9 and 13. Install lifting lugs, part no. 104 589 00 40 00. Lift off cylinder head with engine hoist and lifting tackle.
      Fig 26: Removing Camshaft Bearing Caps

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   4. 27 Clean contact surface on crankcase and on cylinder head.
   5. 28 Replace cylinder head gasket.

      

      The cylinder head gasket is not watertight until the engine has reached operating temperature, in other words, until a swelling operation has taken place. For this reason, the cooling system must not be pressure-tested until after the engine has reached operating temperature.

      Cylinder head identification	Engine 104.98	Engine 104.99
      	104 016 16 20	104 016 17 20

      Fig 27: Identifying Cylinder Head Identification Part No. And Identification Recesses

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      Installation note 

      Pay attention to dowel pins for locating cylinder head on crankcase.

   6. 29 Rotate camshafts so that bottom edge of holes in camshaft flange form a level with top edge of the cylinder head and check with 4 mm pins (1).
      Fig 28: Identifying Pins

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   7. 30 Check TDC position of piston in cylinder 1.
      Fig 29: Identifying TDC Position Of Piston In Cylinder 1

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   8. 31 Fit on cylinder head with lifting tackle.
   9. 32 Examine cylinder head bolts (01-4050) .
   10. 33 Oil the thread and the bolt head contact surface of the cylinder head bolts and insert.
   11. 34 Tighten cylinder head bolts in stages in the order of the tightening diagram, beginning with 1 (01-4050) .
   12. 35 Fit on timing chain, pay attention to markings.
   13. 36 Remove pins from the camshaft flange.
   14. 37 Install in reverse order.