AR01.30-P-5800A Remove/install cylinder head 27.7.
94
ENGINE 111 in MODEL 124, 163, 170, 202, 208, 210
P01.30-0245-09
P01.30-0345-09
Modification notes
1.8.97 Technical modification: bolts+washers of cylinder head to Step 25
timing case cover are replaced by Torx bolts without washer
ed Remove/Install
1 Drain coolant at crankcase AR20.00-P-1142HG
2.1 Remove coolant expansion reservoir Model 163
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3 Unbolt exhaust system at exhaust manifold Model 163
Model 170 AR49.10-P-7000G
Model 124, 202 AR49.10-P-7000D
Model 208 AR49.10-P-7000DA
Model 210 AR49.10-P-7000BA
4.1 Unbolt bracket of exhaust manifold at Engines fitted with bracket of exhaust manifold
transmission at transmission
5 Remove cover of coolant thermostat housing
6 Unplug electrical connections at the cylinder head AR01.30-P-5800-08A
7 Unbolt intake manifold (19), swivel to the side Engine 111.943/973 in Model 170 AR09.20-P-1310GB
with lines connected Engine 111.944/975 as of 09.96 in Model 202
Engine 111.975 in Model 208
Engine 111.947 in Model 210
(engines with plastic intake manifold)
Engine 111.920/940/941/944/975 up to 08.96 AR09.20-P-1310G
Engine 111.960/961 (engines with aluminum
intake manifold)
Engine 111.921/942/945/946/970/974/977 AR09.20-P-1310GA
(engines with plastic intake manifold)
8 Detach crankcase ventilation line i Below flange connection of intake AR01.30-P-5800-06A
manifold/cylinder head
9.1 Separate plug connections of partial intake Engine 111.940 up to 07.93 AR01.30-P-5800-05A
manifold preheater Engine 111.960 up to 08.93
10.1 Unscrew 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 AR01.30-P-5700A
13 Unbolt dipstick guide tube (7)
14.1 Unbolt dipstick guide tube (8) i If automatic transmission fitted
15 Position crankshaft to 20° - 30° after ignition
TDC of cylinder 1
16 Lock camshafts (75 and 78) in place with l *111589031500
locating pins (01)
17 Mark camshaft sprockets and timing chain with p Installation: Fit on timing chain so that the
colored marking color codings on the timing chain and on the
camshaft sprockets are positioned one above
the other
18 Remove chain tensioner (14) p Installation: AR05.10-P-7800A
Prepare chain tensioner for installation.
19 Remove guide rail in cylinder head AR05.10-P-8432A
20 Remove exhaust camshaft sprocket (76) l *000589011000
n *BA05.20-P-1001-02A
p Replace bolts of camshaft sprocket; use
only once
21.1 Remove inlet camshaft sprocket (74) l Engines not fitted with camshaft adjuster *000589011000
n *BA05.20-P-1001-02A
p Replace bolts of camshaft sprocket; use
only once
22.1 Remove inlet camshaft with camshaft adjuster Engine fitted with camshaft adjuster AR05.20-P-6992A
23 Bolt on bracket (16) for removing cylinder head l *104589004000
i Unbolt 1st camshaft bearing cap and bolt on
bracket (16) with bearing cap bolts.
n *BA05.20-P-1004-02A
24 Pull out guide rail pins (11) l AR01.30-P-5800-04A
p Installation: Apply sealant to the slide rail *BR00.45-Z-1014-01A
pins
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25 Remove bolts (A) of cylinder head to timing case n *BA01.40-P-1002-01G
cover in chain housing p Installation: Replace bolts (A), replace bolts
+ washers on engines as of 1994 (bolt head
contact surface enlarged, 17 mm)
with Torx bolts without washer.
Oil bolt head contact surface, tighten bolts
to specified torque and tightening angle.
l *000589011000
k Modified bolts (Torx bolts) for cylinder head to BT01.30-P-0002-01A
timing case cover
26 Slacken cylinder head bolts (12) in stages, l *617589001000
unscrew
p Slacken cylinder head bolts in the
reverse order of the tightening diagram only
once engine has cooled down.
Tightening diagram of cylinder head bolts AR01.30-P-5800-01A
l *617589001000
i Installation: Oil thread and bolt head
contact surface of cylinder head bolts, insert,
tighten in stages
n It is not necessary to retighten the cylinder *BA01.30-P-1002-01B
head bolts.
27 Check cylinder head bolts (12) o AR01.30-P-5800-03HA
28 Attach engine hoist to bracket (16) and to rear k *WH58.30-Z-1001-07A
engine lifting eye
k If necessary model 210: Use engine *WH58.30-Z-1003-07A
supporting frame
29 Raise cylinder head with engine hoist, remove p Installation: Inspect cylinder head gasket
(88), replace.
p When fitting on cylinder head, pay attention
to guide rails; tie guide rails together, if necessary.
p Pay attention to dowel sleeves (15) for
locating cylinder head.
i Engine 111.940/960 with staged front dowel
pin
Remove/install staged dowel pin AR01.30-P-5800-10A
30 Clean contact surfaces, inspect for cracks and If necessary face-grind cylinder head separating AR01.30-P-7162A
flatness surface
31 Clean threaded holes p It is important to ensure that the threaded
holes are free of oil and water.
32 Install in the reverse order
a Danger! Risk of accident caused by vehicle starting off Secure vehicle to prevent it from moving. AS00.00-Z-0005-01A
by itself when engine is running. Risk of injury Wear closed and snug-fitting work clothes.
caused by contusions and burns when working Do not grasp hot or rotating parts.
in engine during starting procedure
33 Run engine and inspect for leaks
34 Inspect cooling system for leaks p Do not pressure-test cooling system until AR20.00-P-1010HA
engine has reached operating temperature.
i The cylinder head gasket is not watertight
until the engine has reached operating
temperature and the gasket has swollen.
Cylinder head/cylinder head bolts
Number Designation Engine
111
BE01.30-P-1001-04B Cylinder head bolt Thread diameter M 12
Length (L) when new mm 102
Length (L) mm 105
Fig. see AR01.30-P-5800-03HA
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n Cylinder head
Number Designation Engine 111
BA01.30-P-1002-01B Bolt of cylinder head M12 1st stage Nm 55
2nd stage ° 90
Step 3 ° 90
Fig. see AR01.30-P-5800-01A
n Crankcase, timing case cover, end cover
Number Designation Engine 111
BA01.40-P-1002-01G Bolt of cylinder head to timing case cover 1st stage Nm 18
Step 2 ° 90
n Camshaft, camshaft adjuster
Number Designation Engine 111
BA05.20-P-1001-02A Bolt of camshaft gear/flange shaft 1st stage Nm 20
Step 2 ° 90
BA05.20-P-1004-02A Bolt of camshaft bearing caps Nm 21
116 589 20 33 00 116 589 01 34 00 104 589 00 40 00 617 589 00 10 00
Impact extractor Threaded pin Retaining clip Screwdriver bit
000 589 01 10 00 111 589 03 15 00 605 589 00 33 00
Torx bit set Retaining pins Extractor
Commercially available tools (see Workshop Equipment Manual)
Number Designation Make (e. g.) Order number
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WH58.30-Z-1001-06A 6 mm socket hexagon of 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 socket hexagon on flexible shaft for hose clamps with worm drive Hazet 426-7
Güldenwerther
Bahnhofstraße 25-28
D-42857 Remscheid
WH58.30-Z-1001-07A Engine hoist (self-locking) Bäcker 3188
Herderstraße
D-42853 Remscheid
WH58.30-Z-1003-07A Engine supporting shackle Erwin Schairer GmbH 0304.01.001
Keltenstraße 9
D-72469 Meßstetten
WH58.30-Z-1004-07A Hook mount Erwin Schairer GmbH 0304.01.005
Keltenstraße 9
D-72469 Meßstetten
Auxiliary repair materials
Number Designation Order number
BR00.45-Z-1014-01A Omnifit FD 3041 sealant (50 ml) 002 989 47 20 10
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