Remove/install cylinder head - AR01.30-P-5800B

ENGINE 112 in MODEL 129 

ENGINE 113 in MODELS 129, 202, 208, 210 

Shown on model 129 with engine 112 

	Remove/install
	Notes on self-locking nuts and bolts	MODEL all	AH00.00-N-0001-01A
	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 running engine	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
	Risk of explosion  caused by oxyhydrogen gas. Risk of poisoning and caustic burns  caused by swallowing battery acid. Risk of injury  caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Disconnect battery ground cable	Installation:  After connecting, read out fault memory, encode radio and normalize power windows. Vehicles with stationary heater: adjust time display on stationary heater.	AR54.10-P-0003A
	Notes on battery	MODEL all	AH54.10-P-0001-01A
2	Remove engine compartment paneling		AR61.20-P-1105AB
	Risk of injury  to skin and eyes caused by scalding from contact with hot coolant spray. 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
3	Drain coolant	At radiator	AR20.00-P-1142HA
4	Remove engine cover or air filter	Model 129, 202.033 /093, 208.370 / 374 /470, 210.074 /274 The air filter is integrated in the engine cover. Remove engine trim panel or air filter by pulling it vertically up and off the cylinder head covers.
5	Remove viscous fan (1)	Right-hand thread!	AR20.40-P-5660C
6	Remove fan shroud (2).
7	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
8	Remove air filter housing (4).	Models 210.070/ 270
9	Remove resonance tube (5) and resonance unit (6)	Do not damage plastic bracket.
		The resonance pipe is attached at the rear at the intake manifold with a plastic plate.
		Separate plug connection of hot film mass air flow sensor (HFM-SFI) for this step and Unbolt resonance pipe at cylinder head cover.
		Models 210.070/ 270	AR07.07-P-1454A
10	Remove hot film mass air flow sensor (HFM-SFI)	Model 129, 202., 208./470, 210.074/ 274	AR07.07-P-1454AG
	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
11	Disconnect fuel line at fuel rail	Release fuel pressure through service valve! Collect fuel.
		M112	*BA07.52-P-1001-01A
		M113	*BA07.52-P-1001-01A
		Pressure hose	Fig 13
12	Remove ignition coils (8, 10)		AR15.12-P-2003A
13	Remove cylinder head covers (7, 9)	Models 210.070/ 270	AR01.20-P-5014B
		Model 129, 202., 208./470, 210.074/ 274	AR01.20-P-5014BV
14	Remove intake manifold (13)	The intake manifold system must not be disassembled. Installation:  On vehicles with engine damage, the intake manifold must be inspected for swarf before assembly and any swarf present must be removed.	AR09.20-P-1310A
		Remove intake manifold together with fuel rail.
15	Remove camshaft position sensor (14)	Only necessary if right cylinder head is removed.	AR15.10-P-2000A
16	Remove poly-V-belt (3)	Installation:  Lock tensioning device with a drift or pin (diameter 5 mm).	AR13.22-P-1202B
17	Detach coolant line (15) at left cylinder head	On Model 202. an additional coolant line is attached at the right cylinder head. The coolant line at the right cylinder head leads to an external transmission oil cooler located on the right, behind the front apron.
		Wrench hexagon	*WH58.30-Z-1001-06A
		Wrench hexagon	*WH58.30-Z-1002-06A
18	Detach exhaust system at exhaust manifold	Installation:  On vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed before installing.
			*BA14.10-P-1002-01B
19	Position crankshaft to 40° after ignition TDC of cylinder 1	Engine must not be cranked back. Rotate engine at crankshaft in direction of rotation until 40° marking on belt pulley/ vibration damper is aligned with marking on timing case cover. The grooves on the camshafts must be pointing toward the inner V.	AR05.10-P-6858V
20	Lock camshafts with locating plate	Locating plate	Fig 5
		Locating plate	Fig 6
21	Remove oil filter housing (18) with oil/water heat exchanger	Models 129, 208 with engine 113	AR18.20-P-3471B
22	Remove chain tensioner (12)		AR05.10-P-7800C
23	Remove camshaft sprockets (16)	If the camshaft sprockets are removed, the engine must no longer be cranked otherwise the timing chain might jam. Model 129, 208 with Engine 113: Tie timing chain tight on both camshaft sprockets with cable straps. All except model 129, 208 with engine 113. Right camshaft sprocket: Tie timing chain tight on camshaft sprocket with cable strap. Left-hand camshaft sprocket: Mark camshaft sprocket to timing chain and remove camshaft sprocket. It is not possible for the timing chain to jump across at the crankshaft and balancing shaft.
		Open-endwrench	Fig 7
		Insertion tool	Figure
		Torque wrench	Fig 11
		After installation: ↓	*BA05.20-P-1001-01B
		Inspect basic position of camshafts. Necessary after checking: ↓	AR05.10-P-6858V
		Set the basic position of camshafts.	AR05.20-P-6020AU
24	Remove camshaft bearing bridges (17)		AR05.20-P-7103AU
25	Unscrew bolts (20) of cylinder head to timing case cover		*BA01.40-P-1002-01C
26	Slacken cylinder head bolts (21) in stages, unscrew	Slacken cylinder head bolts as specified in slackening diagram once engine has cooled down.	AR01.30-P-5800-09B
		Installation:  Observe tightening pattern and tightening instructions of cylinder head bolts. Oil thread and head contact surface of cylinder head bolts.	AR01.30-P-5800-07B
		Screwdriver bit	Figure
		Screwdriver bit	Figure
			*BA01.30-P-1001-01D
27	Remove cylinder head	Installation:  On Engine 113 sealing compound must be applied on the left cylinder head gasket due to porous points in the left cylinder head.
	Information on applying sealant to cylinder head gasket	Engine 113	AH01.30-P-1000-04V
		Loctite 5900 sealant. The sealant must be applied within 10 minutes.	*BR00.45-Z-1013-01A
	Information on cylinder head contact surface	Engine 112, 113	AH01.30-P-1000-05A
28	Inspect version of cylinder head gasket	Assignment of cylinder head gasket Engine 112, 113	AH01.30-P-1000-06V
	Checking
29	Check cylinder head bolts (21)		AR01.30-P-5800-03B
30	Clean sealing surfaces, check for cracks, shrink holes and flatness, clean bolt holes	Pay attention to dowel sleeves (26) for locating the cylinder head.	*BR00.45-Z-1013-01A
		Loctite sealant 5900 Sealing surfaces of 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.
31	Install in the reverse order
32	Run engine and inspect for leaks
33	Inspect cooling system for leaks	Warm up engine to operating temperature and then inspect cooling system or leaks.	AR20.00-P-1010HA
34	Read out fault memory and erase	Stored faults which can result from cables being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work: ↓ Diagnosis Manual Volume 2 Index 0: Connecting and using test equipment. Star-Diagnosis

Number	Designation		Engine 112 except 112.951/ 976	Engine 112.951/ 976
BA01.40-P-1002-01C	Bolt, cylinder head to timing case cover	Nm	20	20

Number	Designation		Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992/995	Engine 113.987/ 988/990/ 991/993
BA01.40-P-1002-01C	Bolt, cylinder head to timing case cover	Nm	20	20

Number	Designation			Engine 112.910/911/ 912/913/914/ 915/916/917/ 920/921/922/ 923/940/941/ 942/943/944/ 945/946/947/ 949/951/953/ 954/955/960/ 961/970/972/ 973/975/976	Engines 113.940/941/ 942/943/944/ 948/960/961/ 962/963/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992	Engine 113.987/ 988	Engine 113.990/991/992/993/995
BA01.30-P-1001-01D	Bolt, cylinder head to crankcase	Stage 1	Nm	10	10	10	10
		Stage 2	Nm	30	30	30	30
		Stage 3	∠°	90	90	90	90
		Stage 4	∠°	90	90	90	90

Number	Designation				Engine 112 except 112.951/976	Engine 112.951/ 976
BA05.20-P-1001-01B	Bolt, camshaft sprocket	M12x45	Stage 1	Nm	50	50
			Stage 2	∠°	90	90

Number	Designation				Engines 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	Bolt, camshaft sprocket	M12x45	Stage 1	Nm	50
			Stage 2	∠°	90

Number	Designation				Engine 113.987/988/ 990/993	Engine 113.991
BA05.20-P-1001-01B	Bolt, camshaft sprocket	M12x45	Stage 1	Nm	50	50
			Stage 2	∠°	90	90

Number	Designation		Engine 112 except 112.945/951/ 960/961
BA07.52-P-1001-01A	Disconnect fuel feed line at fuel rail	Nm	38

Number	Designation		Engine 113.987	Engines 113.990/ 991	Engine 113.990/ 993/995	Engines 113.940/941 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/988
BA07.52-P-1001-01A	Disconnect fuel feed line at fuel rail	Nm	38	38	38	38

Number	Designation		Engine 112 except 112.951/ 976	Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992/993/ 995
BA14.10-P-1001-01B	Nut to exhaust manifold	Nm	16	16
BA14.10-P-1002-01B	Flange connection, exhaust manifold and front exhaust pipes	Nm	20	20
BA14.10-P-1003-01B	Bolt to exhaust manifold	Nm	-	20
BA14.10-P-1004-01B	Collar nut of exhaust manifold to cylinder head	Nm	-	-

Number	Designation
WH58.30-Z-1001-06A	6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A	7 mm socket hexagon on flexible shaft for hose clamps with worm drive

Number	Designation	Order number
BR00.45-Z-1013-01A	Sealant	A 003 989 98 20