AR01.30-P-5800MV Remove/Install Cylinder Head
Remove/install cylinder head
Shown On Model 163.154 With Engine 112, Part 1:
Shown On Model 163.154 With Engine 112, Part 2:
Shown On Model 163.154 With Engine 112, Part 3:
CAUTION: Notes on self-locking nuts and bolts
DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries.
- No fire, sparks, naked flames or smoking. Wear protective gloves, acid-resistant clothing and safety glasses. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect ground cable of battery
NOTE: Installation:
- After connecting, read out fault memory, encode radio and normalize power windows.
- Vehicles with stationary heater: Adjust time of stationary heater timer.
DANGER:
- Lethal injuries are possible If vehicle slips off of lifting platform
- Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.
2 Place the vehicle on lifting platform
3 Remove air guide (1)
NOTE: Only on Engine 113.942
DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.
4 Drain coolant.
NOTE: Detach coolant hose at bottom of radiator.
5 Remove engine trim panel
6 Remove viscous fan (2)
NOTE: Right-hand thread!
7.1 Remove the fan shroud (3).
NOTE: Only Model 163.154/157 /172. unscrew bolts (4) of bottom fan shroud.
7.2 Remove electric fan.
8 Attach guard plate for radiator/condenser
9 Remove air cleaner housing (5)
10 Remove air intake tube (6) with resonance body (7)
NOTE:
- For this step disconnect connector of hot film mass air flow sensor (HFM) and unscrew air intake tube at cylinder head cover.
- The air intake tube is attached at the rear of the intake manifold with a plastic strap.
- Do not damage the plastic strap.
DANGER:
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.
- No fire, sparks, naked flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.
11 Disconnect fuel line at fuel rail
NOTE:
- Release fuel pressure at service valve!
- Collect fuel!
12 Remove right and left ignition coil (12)
13 Remove right and left cylinder head cover (13)
14 Remove intake manifold (14)
CAUTION: Installation: On vehicles with engine damage, the intake manifold must be examined for swarfs before assembling and any swarfs present must be removed, in order to avoid consequential damage.
NOTE:
- The intake manifold system must not be disassembled.
- Remove intake manifold together with fuel distributor.
15 Remove camshaft position sensor (15)
NOTE: Only necessary if the right cylinder head is removed.
16 Remove poly V-belt (8)
NOTE: Installation: Lock tensioning device with a drift or pin (diameter 5 mm).
17 Remove coolant line (16) at left cylinder head.
18 Remove fender liner (9)
NOTE: Only on Engine 113.942/965/981.
19 Remove shield (10)
NOTE: Only on Engine 113.942/965/981.
20 Remove exhaust bracket (11)
NOTE:
- Only on Engine 113.942/965/981.
- Support exhaust system.
21 Disconnect exhaust system from exhaust manifold
CAUTION: Installation: On vehicles with engine damage, the exhaust system must be examined for swarfs before assembling and any swarfs present must be removed, in order to avoid consequential damage.
22 Position crankshaft to 40 degrees at ignition TDC on 1st cylinder
CAUTION: The engine must not be turned back; otherwise the timing chain can get jammed.
NOTE:
- Rotate engine at crankshaft in direction of rotation until 40 degrees 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.
23 Lock camshafts with locating plates
24 Remove chain tensioner (17)
25 Remove oil filter housing (18) together with oil-water heat exchanger.
26 Unscrew camshaft sprockets (19)
CAUTION: If the camshaft sprockets are removed, the engine must no longer be cranked otherwise the timing chain might jam.
NOTE:
- Engine 113.942 /965 /981: Tie timing chain tight on both camshaft sprockets with cable straps.
- Engine 112.942/970: 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.
NOTE:
- It is not possible for the timing chain to jump across at the crankshaft and balancing shaft.
- After installation: Inspect basic position of camshafts.
- If necessary after checking: Set the basic position of camshafts
27 Remove camshaft bearing bridges (28)
NOTE: Observe slackening and tightening pattern!
28 Unscrew bolts of cylinder head -> Stiming case cover (20)
29 Slacken cylinder head bolts (21) in stages, unscrew
CAUTION: Slacken cylinder head bolts according to loosening pattern only on cooled off engine, in order to avoid, that the cylinder head is warping.
NOTE: Installation:
- Observe tightening pattern and tightening instructions of cylinder head bolts.
- Oil thread and head contact surface of cylinder head bolts.
30 Remove cylinder head
NOTE: Installation: On Engine 112/113 it is important to pay attention to porous points in left and right cylinder head. If porous points are present, sealant must be applied to the cylinder head gasket.
CAUTION: Notes on application of sealant to cylinder head gasket.
NOTE:
- The sealant must be applied within 10 minutes.
- Loctite 5900 sealant.
31 Inspect version of cylinder head gasket
- Assignment of cylinder head gasket
NOTE: Information for assigning the cylinder head gaskets
32 Check cylinder head bolts (21)
33 Clean sealing surfaces, inspect for cracks, shrink holes and flatness, clean threaded holes.
NOTE:
- Pay attention to dowel sleeves (26) for locating the cylinder head.
- Sealing surfaces of crankcase and cylinder head are provided with an 0.8 mm thick silicone layer during series production. At the time of repair installation, silicone sealant is applied to the sealing area only in case of any shrink holes.
- The sealant must be applied within 10 minutes.
- Loctite 5900 sealant.
34 Install in the reverse order
DANGER:
- Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury as working around the engine during start-up or whinjury asing may result in contusions and burns.
- Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.
35 Run engine and inspect for leaks
36 Inspect cooling system for leaks
NOTE: Warm up engine to operating temperature and then inspect cooling system or leaks.
37 Read fault memory, erase
NOTE: 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.