AR01.30-P-5800A Remove/install cylinder head 10.11.

11
ENGINES 111 in MODELS 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

Remove/install
1 Drain coolant at crankcase AR20.00-P-1142HG
2.1 Remove coolant expansion reservoir Model 163
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

© Daimler AG, 10/16/19, X/10/19, ar01.30-p-5800a, Remove/install cylinder head Page 1 of 4

ENGINES 111 in MODELS 124, 163, 170, 202, 208, 210
4.1 Unbolt bracket for exhaust manifold at Engines fitted with bracket of exhaust
transmission manifold at transmission
5 Remove cover of coolant thermostat housing
6 Unplug electrical connections at the cylinder AR01.30-P-5800-08A
head
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 Below flange connection of intake AR01.30-P-5800-06A
manifold/cylinder head
9.1 Disconnect 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 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 AR01.30-P-5700A
13 Unbolt dipstick guide tube (7)
14.1 Unbolt dipstick guide tube (8) If automatic transmission fitted
15 Position crankshaft to a 20° - 30° crank angle
after ignition TDC on cylinder 1
16 Lock camshafts (75 and 78) in place with *111589031500
locating pins (01)
17 Mark camshaft sprockets and timing chain Installation: Place timing chain in such a
with colored marking way that the color codings on the timing chain
and on the camshaft sprockets lie one above
the other.
18 Remove chain tensioner (14) Installation: AR05.10-P-7800A
Prepare chain tensioner for installation.
19 Remove slide rail in cylinder head AR05.10-P-8432A
20 Remove exhaust camshaft sprocket (76) *000589011000
*BA05.20-P-1001-02A
Replace screw/bolts for camshaft
sprocket; use only once.
21.1 Remove inlet camshaft sprocket (74) Engines not fitted with camshaft adjuster *000589011000
*BA05.20-P-1001-02A
Replace screw/bolts for camshaft
sprocket; use only once.
22.1 Remove inlet camshaft with camshaft adjusterEngine fitted with camshaft adjuster AR05.20-P-6992A
23 Screw/bolt on bracket (16) for removing *104589004000
cylinder head
Unbolt 1st camshaft bearing cap and
screw on bracket (16) using bearing cap bolts.
*BA05.20-P-1004-02A
24 Remove slide rail pins (11) AR01.30-P-5800-04A
Installation: Apply sealant to the slide rail *BR00.45-Z-1012-01A
pins
25 Unscrew screw/bolts (A) of cylinder head to *BA01.40-P-1002-01G
timing case cover in chain housing Installation: Replace screw/bolts (A),
bolts and washers for engines as of 1994
(enlarged bolt head contact surface,
17 mm) with Torx bolts without washers.
Oil bolt head contact surface, tighten
Screw/bolts to specified torque and
tightening angle.
*000589011000
Modified bolts (Torx bolts) for cylinder head to BT01.30-P-0002-01A
timing case cover
26 Slacken cylinder head bolts (12) in *617589001000
increments, unscrew Slacken cylinder head bolts in the
reverse order of the tightening procedure
only once engine has cooled down.
Tightening procedure for cylinder head bolts AR01.30-P-5800-01A
*617589001000
Installation: Oil thread and bolt head
contact surface of cylinder head bolts, insert,
tighten in stages
© Daimler AG, 10/16/19, X/10/19, ar01.30-p-5800a, Remove/install cylinder head Page 2 of 4
ENGINES 111 in MODELS 124, 163, 170, 202, 208, 210
 It is not necessary to retighten the cylinder *BA01.30-P-1002-01B
head bolts.
27 Check cylinder head bolts (12) AR01.30-P-5800-03HA
28 Attach engine hoist to bracket (16) and to rear Load regulator
engine lifting eye gotis://H_00.12_04.0
If necessary for model 210: Use engine
supporting frame
29 Raise cylinder head with engine hoist, remove 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 the cylinder head.
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 andFace-grind cylinder head separating surface if AR01.30-P-7162A
flatness necessary
31 Clean threaded holes 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 caused by vehicle starting Secure vehicle to prevent it from moving by AS00.00-Z-0005-01A
off by itself when engine is running. Risk of itself.
injury caused by contusions and burns during Wear closed and snug-fitting work clothes.
starting procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
33 Check for leaks with engine running
34 Inspect cooling system for leaks Do not pressure-test cooling system until AR20.00-P-1010HA
engine has reached operating temperature.
As 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 Thread diameter M 12

bolt

Length (L) when new mm 102

Length (L) mm 105

See picture AR01.30-P-5800-03HA

Cylinder head

Number Designation Engine 111

BA01.30-P-1002-01B Screw/bolt, cylinder head M12 Stage 1 Nm 55

Stage 2 ° 90

Stage 3 ° 90

See picture AR01.30-P-5800-01A

Crankcase, timing case cover, end cover

Number Designation Engine

111

© Daimler AG, 10/16/19, X/10/19, ar01.30-p-5800a, Remove/install cylinder head Page 3 of 4

ENGINES 111 in MODELS 124, 163, 170, 202, 208, 210
 BA01.40-P-1002-01G Screw/bolt, cylinder head to timing case cover Stage 1 Nm 18

Stage 2 ° 90

Camshaft, camshaft adjustment

Number Designation Engine

111

BA05.20-P-1001-02A Screw/bolt for camshaft sprocket/ Stage 1 Nm 20

flange shaft

Stage 2 ° 60

BA05.20-P-1004-02A Screw/bolt for camshaft bearing cap 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 stud Retaining clip Screwdriver bit

000 589 01 10 00 111 589 03 15 00 605 589 00 33 00

Torx bit set Retaining pins Puller

Repair materials
Number Designation Order number
BR00.45-Z-1012-01A Sealant, Omnifit FD 3041 A 002 989 47 20 10

© Daimler AG, 10/16/19, X/10/19, ar01.30-p-5800a, Remove/install cylinder head Page 4 of 4

ENGINES 111 in MODELS 124, 163, 170, 202, 208, 210