AR01.30-P-5800A Remove/Install Cylinder Head
Removing, Installing Cylinder Head
Part 1:
Part 2:
1 Drain coolant at crankcase
2 Remove coolant expansion reservoir
- Model 163
3 Unbolt exhaust system at exhaust manifold
4 Unbolt bracket of exhaust manifold at transmission
- Engines fitted with bracket of exhaust manifold at transmission
5 Remove cover of coolant thermostat housing
6 Unplug electrical connections at the cylinder head
7 Unbolt intake manifold (19), swivel to the side with lines connected
8 Detach crankcase ventilation line
NOTE: Below flange connection of intake manifold/cylinder head
9 Separate plug connections of partial intake manifold preheater
10 Unbolt bracket (2)
- Engine 111 with aluminum intake manifold
11 Detach coolant hose (3) at rear of cylinder head
12 Remove front cover at cylinder head
13 Unbolt dipstick guide tube (7)
14 Unbolt dipstick guide tube (8)
NOTE: If automatic transmission fitted
15 Position crankshaft to 20 degrees - 30 degrees after ignition TDC of cylinder 1
16 Lock camshafts (75 and 78) in place with locating pins (01)
17 Mark camshaft sprockets and timing chain with colored marking
CAUTION: Installation: Fit on timing chain so that the colored markings on the timing chain and on the camshaft sprockets are positioned one above the other.
18 Remove chain tensioner (14)
CAUTION: Installation: Prepare chain tensioner for installation.
19 Remove guide rail in cylinder head
20 Remove exhaust camshaft sprocket (76)
CAUTION: Replace bolts of camshaft sprocket, use only once.
21 Remove inlet camshaft sprocket (74)
CAUTION: Replace bolts of camshaft sprocket, use only once.
22 Remove inlet camshaft with camshaft adjuster
- Engine fitted with camshaft adjuster
23 Bolt on bracket (16) for removing cylinder head
NOTE: Unbolt 1st camshaft bearing cap and bolt on bracket (16) with bearing cap bolts.
24 Remove guide rail pins (11)
CAUTION: Installation: Coat guide rail pins with sealant
25 Remove bolts (A) of cylinder head to timing case cover in chain housing
CAUTION: Installation: Replace bolts (A). Replace bolts + washers on engines as of 1994 (bolt head contact surface enlarged, 17 mm) diameter with torx bolts without washer.
- Oil bolt head contact surface, tighten bolts to specified torque and tightening angle.
26 Slacken cylinder head bolts (12) in stages and unscrew
CAUTION: Slacken cylinder head bolts in the reverse order of the tightening diagram only once engine has cooled down.
NOTE: Installation: Oil thread and head contact surface of cylinder head bolts, insert and tighten in stages.
- It is not necessary to retighten the cylinder head bolts.
27 Inspect cylinder head bolts (12)
28 Attach engine hoist to bracket (16) and to rear engine lifting eye
- If necessary model 220: Use engine supporting frame
29 Raise cylinder head with engine hoist, remove
CAUTION:
- Installation: Inspect cylinder head gasket (88), replace.
- When fitting on cylinder head, pay attention to guide rails; tie guide rails together, if necessary.
- Pay attention to dowel sleeves (15) for locating cylinder head.
NOTE: Engine 111.940/960 with staged front dowel pin, Removing, installing staged dowel pin
30 Clean contact surfaces, inspect for cracks and flatness
- if necessary machine cylinder head contact surface
31 Clean threaded holes
CAUTION: It is important to ensure that the threaded holes are free of oil and water.
32 Install in the reverse order
DANGER:
- Risk of accident from vehicle starting off by itself when engine running. Risk of injury from bruises and burns if you hold your hand into engine when it is started or when it is running.
- Secure vehicle to prevent it moving off by itself.
- Wear closed and dose-fitting work clothes.
- Do not grasp hot or rotating parts.
33 Run engine and inspect for leaks
34 Inspect cooling system for leaks
CAUTION: Do not pressure-test cooling system until engine has reached operating temperature.
NOTE: The cylinder head gasket is not watertight until the engine has reached operating temperature and the gasket has swollen.