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

ENGINE 112 in MODELS 170, 202, 208, 210, 220 

ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475 

Shown on model 220 with engine 112 

Fig 1: Identifying Cylinder Head Components (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cylinder Head Components (2 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	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	Models 170, 202, 208, 210	AR54.10-P-0003A
		Model 211.076	AR54.10-P-0003T
		Model 211.276	AR54.10-P-0003TA
		Model 215, 220	AR54.10-P-0003I
		Model 230.474/475	AR54.10-P-0003R
	Notes on battery	All models Turnkey in electronic ignition switch EIS into position "0". Key cannot be withdrawn. Vehicle with Keyless Go code 889: Switch off engine, remove Keyless Go cards from the vehicle and keep outside the range of the transmitter. Installation:  After connecting, read out fault memory, set the time in the instrument cluster, code radio, normalize power windows and tilting/sliding roof and activate steering angle sensor. Vehicles with stationary heater: Adjust the time on the stationary heater control.	AH54.10-P-0001-01A
2	Remove engine compartment paneling	Model 202, 208, 210	AR61.20-P-1105AB
		Model 170	AR61.20-P-1105A
		Model 211	AR61.20-P-1105T
		Model 215, 220	AR61.20-P-1105M
		Model 230	AR61.20-P-1105R
	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	Engine 112 in models 202, 208, 210, 220, Engine 113 (except 113.991) in Model 220, Engine 113.963 in model 230.475	AR20.00-P-1142HA
		Engine 112 in Model 170	AR20.00-P-1142SV
		Engine 113.990 in model 211.076/276, Engine 113.991 in models 215.374, 220.074/174/874 Engine 113.992 in model 230.474	AR20.00-P-1142RVK
4.1	Remove engine trim panel with integrated air filter	Model 170.465, Models 202, 208, 210, Model 220 except 220.074/174, Model 230.475 Unclip cover on front end of engine.
4.2	Remove air filter	Model 170.466 Model 211.076/276, Models 215.374, 220.074/174, Model 230.474	AR09.10-P-1150SVK
5.1	Remove fan shroud (2) with electric fan (1)	Before removing the fan shroud (2), disconnect connector for electric fan (1).
		Model 211	AR20.40-P-6800TC
		Model 215, 220, 230	AR20.40-P-6800AB
6.1	Remove resonance tube (5) and resonance unit (6)	In the process separate the connector of the hot film mass air flow sensor and unscrew the resonance pipe (5) on the cylinder head cover. The resonance pipe (5) is fastened to the back of the intake manifold (13) with a plastic strap. Do not damage the plastic strap.
		Engine 112.910 in models 202.026/086, Engine 112.920 in models 202.029/089, Engine 112.911 in models 210.061/261, Engine 112.921 in model 210.063/263/ 081/281/663, Engine 112.941 in model 210.065/082/ 265/282, Engine 112.940 in model 208.365/465	AR07.07-P-1454A
7.1	Remove hot film mass air flow sensor	Engine 112.947 in model 170.465	AR07.07-P-1454AG
		Engine 112.922 in model 220.063, Engine 112.944 in models 220.065/165, Engine 112.972 in models 220.067/167, Engine 112.975 in models 220.087/187, Engine 113.941 in models 220.070/170, Engine 113.948 in models 220.083/183, Engine 113.960 in models 220.075/175, Engine 113.963 in model 230.475, Engine 113.966 in model 220.084/184	AR07.07-P-1454AA
	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
8	Disconnect fuel line at fuel rail	Release fuel pressure through service valve! Collect fuel! Engine 112
		Engine 113	*BA07.52-P-1001-01A
			*BA07.52-P-1001-01A
		Pressure hose	Figure
9	Remove right ignition coils (8) and left ignition coils (10)	Engine 112.910 in models 202.086/026, Engine 112.920 in models 202.029/089, Engine 112.921 in model 210.063/081/ 263/281, Engine 112.922 in model 220.063, Engine 112.940 in models 208.465/365, Engine 112.941 in model 210.265/065/ 082/282, Engine 112.944 in models 220.065/165, Engine 113.940 in models 210.070/270, Engine 113.941 in models 220.070/170, Engine 113.960 in models 215.375, 220.175 /075/875, Engine 113.943 in models 208.470/370, Engine 113.984 in model 208.374, Engine 112.947 in model 170.465, Engine 112.960 in model 170.466, Engine 113.986 in model 220.173, 215.373, 220.073, Engine 113.963 in model 230.475, Engine 112.913 in models 211.061/261, Engine 112.949 in models 211.065/265, Engine 113.967 in model 211.070, Engine 113.992 in model 230.474, Engine 113.990 in model 211.076/276, Engine 113.991 in models 220.174/074, 215.374 Engine 112.972 in models 220.167/067, Engine 112.973 in model 230.467, Engine 112.975 in models 220.087/187, Engine 113.948 in models 220.083/183, Engine 113.966 in model 220.084/184	AR15.12-P-2003A
10	Remove right cylinder head cover (7) and left cylinder head cover (9)	Engines 112, 113 air filter located on vehicle side	AR01.20-P-5014B
		Engines 112, 113 air filter located on engine side	AR01.20-P-5014BV
11.1	Remove compressor	Model 170.466,211.076/276, 215.374, 220.074/174, 230.474	AR09.50-P-4705SVK
11.2	Remove intake manifold (13)	Except models 170.466, 211.076/276, 215.374, 220.074/174, 230.474 Remove intake manifold (13) together with fuel distributor. The intake manifold system must not be disassembled. Installation:  On vehicles with engine damage the intake manifold (13) must be examined for shavings prior to assembly and any shavings removed, otherwise the next engine damage would be preprogrammed.	AR09.20-P-1310A
12.1	Remove camshaft position sensor (14)	Only necessary when removing the right cylinder head (23).
		Engine 112 in Model 170, 202, 208, 210, 220, Engine 113 (except 113.991) in Model 220, 230.474/475	AR15.10-P-2000A
		Engine 113 in Model 211.076/276, 215.374, 220.074/174	AR15.10-P-2000RVK
13.1	Unbolt dipstick guide tube from bracket at cylinder head	Model 211, 215, 220.074/174, 230.474/475
14	Remove poly-V-belt (3)	Installation:  Lock tensioning device with a drift or pin (diameter 5 mm).
		Engine 112 in Model 170	AR13.22-P-1202SV
		Engine 112 in Model 202, 208.365/465, 210, 220.063/065/067/087/165/167/187, Engine 113 in models 220.070/073/075/083/084/170/173/175/183/184/875	AR13.22-P-1202BA
		Engine 113 in model 211.076/276	AR13.22-P-1202RV
		Engine 113 in models 215.374, 220.074/174, 230.474/475	AR13.22-P-1202R
15	Detach coolant line (15) from left cylinder head (22)	On models 202.093/033 an additional coolant line is attached to the right cylinder head (23). The coolant line of the right cylinder head (23) leads to an external transmission oil cooler, the right is located behind the front apron.
		6 mm socket hexagon	*WH58.30-Z-1001-06A
		7 mm socket hexagon	*WH58.30-Z-1002-06A
16	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. Otherwise the catalytic converter would be damaged. Engine 112.915 in model 202 Engine 112.911/914 in model 210
		Engine 112 in model 170	AR49.10-P-7000SV
		Engine 112.910 in models 202.026/086, Engine 112.920 in models 202.029/089, Engine 112.940 in model 208.365/465	AR49.10-P-7000AU
		Engine 112.921/941 in model 210	AR49.10-P-7000A
		Engine 112 in model 220, Engine 113 in model 215.374, 220	AR49.10-P-7000AA
		Engine 113 in model 211.076/276	AR49.10-P-7000TB
		Engine 113 in model 230.474	AR49.10-P-7000RA
		Engine 113 in model 230.475	AR49.10-P-7000R
			*BA14.10-P-1002-01B
17	Position crankshaft at a 40° crank angle after ignition TDC of cylinder 1	The engine must not be turned back, otherwise the timing chain may skip a tooth. 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. If there are no adjusting marks on the camshafts, locating plates are used to adjust the timing.	AR05.10-P-6858V
		Locating plate	*112589003200
		Locating plate	*112589013200
18	Lock camshafts with locating plate	Locating plate	*112589003200
		Locating plate	*112589013200
19.1	Remove oil/water heat exchanger at oil filter	Engine 112 in Model 170, 202, 208, 210, 220, Engine 113 in model 220, Engine 113.963 in model 230.475	AR18.30-P-3481CA
20	Remove oil filter housing	Engine 113.990 in model 211.076/276, Engine 113.991 in models 215.374, 220.074 /174, Engine 113.992 in model 230.474	AR18.20-P-3471RKV
		Engine 112 in Model 170, 202, 208, 210, 220, Engine 113 (except 113.991) in Model 220, Engine 113.963 in model 230.475	AR18.20-P-3471BA
21	Remove chain tensioner (12)	Engine 112 in models 170, 202, 208, 210,	AR05.10-P-7800CA
		Engine 112 in model 220, Engine 113 in models 211, 215, 220, 230	AR05.10-P-7800AM
22	Remove camshaft sprockets (16)	When the camshaft sprockets (16) are removed the engine must not be cranked any more, otherwise the timing chain could be canted over. Right-hand 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.
			*BA05.20-P-1001-01B
		Open-endwrench	*112589000100
		Insertion tool	*112589010300
		Torquewrench After installation: ↓	*001589722100
		Check basic position of camshafts After inspecting, if necessary: ↓	AR05.10-P-6858V
		Set the basic position of camshafts	AR05.20-P-6020AU
23	Remove camshaft bearing bridges (17)	Engines 112, 113 except engine 113.960 with cylinder shutoff, code 479	AR05.20-P-7103AU
		Engine 113.960 with cylinder shutoff code 479	AR05.20-P-7103AV
24	Unscrew bolts, cylinder head → timing case cover (20)		*BA01.40-P-1002-01C
25.1	Take off locating plates and remove camshafts	Models 211, 215, 230.474/475
26	Slacken cylinder head bolts M11x141.5 (21) in stages, unscrew	Slacken cylinder head bolts M11x141.5 (21) according to loosening pattern on a cooled off engine. The cylinder head bolts M11x141.5 (21) would be overstretched otherwise.	AR01.30-P-5800-09B
		Installation:  Observe tightening pattern and tightening instructions of cylinder head bolts M11x141.5 (21). Oil cylinder head bolts M11x141.5 (21) at thread and bolt head contact surface.	AR01.30-P-5800-07B
			*BA01.30-P-1001-01D
		Screwdriver insert	Figure
27	Remove cylinder head
	Information on applying sealant to cylinder head gasket	Engine 113	Sealant AH01.30-P-1000-04V
	Information on applying sealant to cylinder head gasket	Engine 112	AH01.30-P-1000-04VA
	Information on cylinder head contact surface		AH01.30-P-1000-05A
		Installation:  On engine 113 due to porous points in the left cylinder head, sealing compound must be coated on the left cylinder head gasket, otherwise there would be leaks at the left cylinder bank. Installation:  Observe dowel sleeves (26) for locating the cylinder head, otherwise the cylinder head would cant over. Installation:  The sealing compound must be processed within 10 minutes.
		Sealant	*BR00.45-Z-1013-01A
	Checking
28	Inspect version of cylinder head gasket
	Information for assigning the cylinder head gaskets		AH01.30-P-1000-06V
29	Inspect cylinder head bolts M11 x 141.5 (21)		AR01.30-P-5800-03B  *BE01.30-P-1001-04B
30	Clean, check sealing surfaces and tapped holes	Check for cracks, blowhole inclusions, unevenness and damage. 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. Installation:  The sealing compound must be processed within 10 minutes.
		Sealant	*BR00.45-Z-1013-01A
31	Install in the reverse order
	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
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.
		Engine 112 (except 112.947/960) in Model 202, 208, 210, 220.	AR20.00-P-1010HA
		Engine 113 (except 113.991) in Model 220 Engine 113.992 in model 230.474, Engine 113.990 in model 211.076/276, Engine 113.991 in model 215.374, Engine 113.991 in models 220.074/174, Engine 113.963 in model 230.475	AR20.00-P-1010RVK
		Engine 112.947 in model 170.465, Engine 112.960 in model 170.466	AR20.00-P-1010P
34	Read out fault memory and erase	When the work is complete stored faults must be worked on in the diagnostic trouble code memories and erased. The stored faults may be caused by lines removed during assembly or during test work and by a simulation.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
35	Carry out function check

Cylinder head

Cylinder head

Crankcase, timing case cover, end cover

Crankcase, timing case cover, end cover

Camshaft

Camshaft

Camshaft

Camshaft

Fuel rail

Fuel rail

Exhaust manifold

Fig 3: Identifying (001 589 72 21 00) Torque Wrench

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying (119 589 04 63 00) Pressure Hose

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying (112 589 00 32 00) Locating Plate

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying (112 589 01 32 00) Locating Plate

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying (112 589 00 01 00) Open End Wrench

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying (112 589 01 03 00) Insertion Tool

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying (000 589 03 10 00) Screwdriver Insert

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.