AR01.30-P-5800MV Remove/install cylinder head 22.7.

98

ENGINE 112.942 in MODEL 163.154

ENGINE 112.970 in MODEL 163.157
ENGINE 113.942 in MODEL 163.172
ENGINE 113.981 in MODEL 163.174
ENGINE 113.965 in MODEL 163.175

Shown on model 163.154 with engine 112

1 Air baffle
2 Viscous fan
3 Fan shroud
4 Bolts
5 Air cleaner housing
6 Air intake manifold
7 Resonance unit
8 Poly-V-belt
9 Fender liner
10 Shield
11 Exhaust bracket

P01.30-2032-06
12 Right and left ignition coils
13 Left and right cylinder head covers
14 Intake manifold
15 Camshaft position sensor
16 Coolant line
17 Chain tensioner
18 Oil filter housing
19 Camshaft sprockets
28 Camshaft bearing bridges

P01.30-2033-06

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 1
 20 Bolts cylinder head ! timing case cover
21 Cylinder head bolts
22 Cylinder head left
23 Cylinder head right
24 Left cylinder head gasket
25 Right cylinder head gasket
26 Dowel sleeves

P01.30-0299-06

Remove/Install
Notes on self-locking nuts and bolts All models AH00.00-N-0001-01A

External torx set *001589760900

Torx bit set *000589011000

Danger! Risk of explosion caused by oxyhydrogen No fire, sparks, open flames or smoking. AS54.10-Z-0001-01A
gas. Risk of poisoning and caustic burns Wear acid-resistant gloves, clothing and
caused by swallowing battery acid. Risk of safety glasses. Pour battery acid only into
injury caused by burns to skin and eyes from suitable and appropriately marked containers.
battery acid or when handling damaged lead-
acid batteries
1 Disconnect battery ground cable Installation: After connecting, read out AR54.10-P-0003A
fault memory, encode radio and normalize
power windows.
Vehicles with stationary heater: Set time on
timer for stationary heater
Notes on battery All models AH54.10-P-0001-01A

Danger! Risk of death caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A
toppling off of the lifting platform. 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 AR00.60-P-1000GH
3.1 Remove air guide (1) Only with engine 113.942
Danger! Risk of injury to skin and eyes suffering Do not open cooling system unless coolant AS20.00-Z-0001-01A
scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly
Risk of poisoning from swallowing coolant. and release the pressure. Do not pour coolant
into beverage bottles.
Wear protective gloves, protective clothing
and eye protection.
4 Drain coolant Remove coolant hose at bottom on AR20.00-P-1142HA
radiator.
5 Remove engine cover
6.1 Remove viscous fan (2) All except model 163.174 /175 with AR20.40-P-5660C
engine 113.981 /965.

Right-hand thread!
7.1 Remove the fan shroud (3). Only model 163.154 /157 /172. Unscrew
bolts (4) from bottom of fan shroud
7.2 Remove electric fan Only model 163.174/ 175. AR20.40-P-5000GH

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 2
 8 Attach guard plate for radiator/condenser
y Guard plate for radiator/condenser Engine 606 in model 124, WF58.50-P-0110-01A
Engine 606.961 in model 140,
Engine 112, 113, 604, 605, 611.960 in model
202,
Engine 602.983, 612.966 in model 461,
Engine 628.962, 612.965, 606.964, 112.945,
113.962/ 982 in model 463,
Engine 111, 112, 611.962, 612.962 in model
203,
Engine 112, 113, 611.961, 612.961, 613.961
in model 210,
Engine 112 in model 170,
Engine 112 in model 220,
Engine 113 in model 211, 215, 220,
Engine 112 in model 208,
Engine 112, 113, 612.963, 628.963 in model
163,
Engine 112.923 /943, 113.961 in model 129,
Engine 137, 275 in model 215, 220,
Engine 613.960, 628.960 in model 220,
Engine 113.992 in model 230.474,
Engine 271 in model 209, 203,
Engine 285.950 in model 240.078 /178,
Engine 612.967 in model 209.316,
Engine 648 in model 220
Engine 112.951 in model 639.601/603/ 605/
701 /703 /705 /801 /803 /805
Engine 646.983 /984 in model 639.601/
603 /605 /701 /703 /705 /801 /803 /805
Engine 646.982 in model 639.601/ 603/ 605/
701 /703 /705
9 Remove air cleaner housing (5)
10 Remove air intake pipe (6) with resonance Separate connector of hot film mass air
tube (7) flow sensor (HFM) for this step and unbolt air
intake pipe at cylinder head cover

The air intake pipe is attached at the rear

at the intake manifold with a plastic plate.

Do not damage the plastic strap.

Engine 112.942/ 970 AR07.07-P-1454A
Engine 113.942/ 965/ 981 AR07.07-P-1454MV

Danger! Risk of explosion caused by fuel igniting, No fire, sparks, open flames or smoking. AS47.00-Z-0001-01A
risk of poisoning caused by inhaling and Pour fuels only into suitable and appropriately
swallowing fuel as well as risk of injury to marked containers.
eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel.
11 Disconnect fuel line at fuel rail Release fuel pressure at service valve!

Collect fuel!

Engine 112:#
*BA07.52-P-1001-01A
Engine 113:#
*BA07.52-P-1001-01A
Pressure hose *119589046300
12 Remove right and left ignition coils (12) AR15.12-P-2003A

13 Remove right and left cylinder head covers (13) AR01.20-P-5014B

14 Remove the intake manifold (14) Installation: On vehicles with engine AR09.20-P-1310A
damage, the intake manifold must be
examined for swarfs before assembling and
any swarfs present must be removed, in order
to avoid consequential damage.
The intake manifold system must not be
disassembled.

Remove intake manifold with fuel distributor

15.1 Remove camshaft position sensor (15) Only necessary if the right cylinder head is AR15.10-P-2000A
removed.

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 3
 16 Remove poly V-belt (8) Installation: Lock tensioning device with
a drift or pin (diameter 5 mm).
Model 163.154 /157 /172. AR13.22-P-1202B
Model 163.174 /175. AR13.22-P-1202BA
17 Detach the coolant line (16) at the cylinder 6 mm socket hexagon *WH58.30-Z-1001-06A
head on the left
7 mm socket hexagon *WH58.30-Z-1002-06A
18.1 Remove fender liner (9) Only with engine 113.113.942 /965 / 981. AR88.10-P-1300GH

19.1 Remove shield (10) Only with engine 113.942 /965 /981.
20.1 Remove exhaust bracket (11) Only with engine 113.942 /965 /981.

Support exhaust system.

21 Detach exhaust system at exhaust manifold 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.
*BA14.10-P-1002-01B
22 Position crankshaft to 40° after ignition TDC The engine must not be turned back; AR05.10-P-6858V
on cylinder 1 otherwise the timing chain can get jammed.
Rotate engine at the crankshaft in running
direction until scribe mark 40° on pulley/
vibration damper corresponds with scribe
mark on timing case.
The grooves on the camshafts must be
pointing toward the inner V.
23 Lock camshafts with locating plates Locating plate *112589003200

Locating plate *112589013200

24 Remove chain tensioner (17) Model 163.154 /157 with engine 112.942/ AR05.10-P-7800C
970, model 163.172 with engine 113.942.
Model 163.174 /175 with engine 113.981/ 965. AR05.10-P-7800CA
25.1 Remove oil filter housing (18) together with oil- Engine 113.942. AR18.20-P-3471B
water heat exchanger
Engine 112.942/970. AR18.20-P-3471BA
26 Unscrew camshaft sprockets (19) If camshaft sprockets are removed,
engine must no longer be cranked, otherwise
timing chain might jam.

Engine 113.942 /965 /981: #

Tie timing chain tight on both camshaft

sprockets with tie straps.

Engine 112.942 /970: #

Right-hand camshaft sprocket:

Tie timing chain tight on camshaft sprocket
with tie 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.

After installation:#
Inspect basic position of camshafts. AR05.10-P-6858V
If necessary after checking: #
Set the basic position of camshafts AR05.20-P-6020AU
Open-end wrench *112589000100
Insertion tool *112589010300
Torque wrench *001589722100
*BA05.20-P-1001-01B
27 Remove camshaft bearing bridges (28) Pay attention to slackening and tightening AR05.20-P-7103AU
pattern!
28 Unscrew bolts, cylinder head ! timing case *BA01.40-P-1002-01C
cover (20)

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 4
 29 Slacken cylinder head bolts (21) in stages, Loosen cylinder head bolts according to AR01.30-P-5800-09B
unscrew loosening schematic only after engine has
cooled down to prevent cylinder head from
distorting.
Installation: Observe tightening pattern AR01.30-P-5800-07B
and tightening instructions of cylinder head
bolts.
Oil thread and head contact surface of
cylinder head bolts.
Screwdriver insert *000589031000
Screwdriver insert *000589041000
*BA01.30-P-1001-01D
30 Remove cylinder head Installation: On Engine 112/113 observe
porous points in the left and right cylinder
head. If porous points are present, sealant
must be applied to the cylinder head gasket.
Notes on application of sealant to cylinder Engine 112, 113 AH01.30-P-1000-04VA
head gasket.
The sealant must be applied within
10 minutes.
Loctite 5900 sealant. *BR00.45-Z-1015-01A
31 Inspect version of cylinder head gasket Assignment of cylinder head gasket
Information for assigning the cylinder head Engine 112, 113 AH01.30-P-1000-06V
gaskets
32 Check cylinder head bolts (21) AR01.30-P-5800-03B
*BE01.30-P-1001-04B
33 Clean sealing surfaces, inspect for cracks, Pay attention to dowel sleeves (26) for
shrink holes and flatness, clean threaded locating the cylinder head.
holes.

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. *BR00.45-Z-1015-01A
34 Install in the reverse order
Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving. AS00.00-Z-0005-01A
off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes.
injury caused by contusions and burns when Do not grasp hot or rotating parts.
working in engine during starting procedure
35 Run engine and inspect for leaks
36 Inspect cooling system for leaks Warm up engine to operating temperature AR20.00-P-1010HA
and then inspect cooling system or leaks.
37 Read out and erase fault memory 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.

Cylinder head/cylinder head bolts

Number Designation Engine Engine

112.910/911/912/ 113.940/941/
913/914/915/ 942/943/944/
916/917/920/ 945/946/948/
921/922/923/ 960/961/962/
940/941/942/ 963/965/966/
943/944/945/ 967/968/969/
946/947/949/ 980/981/982/
951/953/954/ 984/986/987/
955/960/961/ 988/990/991/
970/972/973/975 992/993

BE01.30-P-1001-04B Cylinder head bolt Thread diameter M 11 11

Length (L) when new mm 141.5 141.5

Length (L) mm T 144.5 T 144.5

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 5
 Fig., see AR01.30-P-5800-03B AR01.30-P-5800-03B

Cylinder head

Number Designation Engine Engine

112.910/911/912/ 113.940/941/
913/914/915/ 942/943/944/
916/917/920/ 948/960/961/
921/922/923/ 962/963/965/
940/941/942/ 966/967/968/
943/944/945/ 969/980/981/
946/947/949/ 982/984/986/
951/953/954/ 992
955/960/961/
970/972/973/975

BA01.30-P-1001-01D Bolt of cylinder head to 1st stage Nm 10 10

crankcase
2nd stage Nm 30 30
3rd stage ( ° 90 90
4th stage ( ° 90 90

Crankcase, timing case cover, end cover

Number Designation Engine Engine

112 113.940/941/
except 942/943/944/
112.951 945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992

BA01.40-P-1002-01C Bolt, cylinder head to timing case cover Nm 20 20

Camshaft

Number Designation Engine Engine

112 113.940/941/
except 112.951 942/943/944/
948/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992

BA05.20-P-1001-01B Bolt of camshaft sprocket M12 x 45 1st stage Nm 50 50

2nd stage ( ° 90 90

Fuel rail

Number Designation Engine

112 except
112.945/951/
960/961

BA07.52-P-1001-01A Fuel feed line to fuel rail Nm 38

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 6
 Fuel rail

Number Designation Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/988/

BA07.52-P-1001-01A Fuel feed line to fuel distributor Nm 38

Exhaust manifold

Number Designation Engine Engine

112 113.940/941/
except 942/943/944/
112.951 945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992/
993

BA14.10-P-1002-01B Flange connection of exhaust manifold or front Nm 20 20

exhaust pipes

001 589 76 09 00 000 589 01 10 00 112 589 00 32 00 112 589 01 32 00

External Torx set Torx bit set Locating plate Locating plate

112 589 00 01 00 112 589 01 03 00 000 589 03 10 00 000 589 04 10 00

Open-end wrench Insertion tool Screwdriver insert Screwdriver insert

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 7
 119 589 04 63 00 001 589 72 21 00

Pressure hose Torque wrench

Commercially available tools (see Workshop Equipment Manual)

Number Designation Make (e. g.) Order number
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive Hazet 426-6
Güldenwerther
Bahnhofstraße 25-28
D-42857 Remscheid
WH58.30-Z-1002-06A 7 mm hexagon socket wrench to flexible shaft for hose clips with worm Hazet 426-7
drive Güldenwerther
Bahnhofstraße 25-28
D-42857 Remscheid

Auxiliary repair materials

Number Designation Order number
BR00.45-Z-1015-01A Loctite sealant 5970 A 003 989 98 20 10

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services. Page 8