Page 1 of 10 AR01.30-P-5800PK Remove/install cylinder head 7.6.00 ENGINE 111.955 in MODEL 203.045 /245 /745 P01.30-2081-09 1 Air filter housing 2 Air recirculation flap actuator 3 Top engine trim panels 4 Cylinder head cover 5 Air scoop 6 Vacuum line 7 Vacuum pump 8 Vacuum line 9 Inlet and pressure connection 10 Clamp 12 Dipstick guide tube 13 Fuel rail with injectors 14 Intake manifold 15 Vacuum line 16 Crankcase ventilation pipe 17 Supercharger 18 Chain tensioner 19 Front exhaust system 20 Screws 21 Exhaust gas recirculation pipe
Page 2 of 10 11 Bracket Y32 Switchover valve P01.30-2082-09 22 Exhaust bracket 23 Coolant line (cylinder head heat exchanger) 24 Clamp 25 Vibration damper 26 Top guide rail 27 Bolts 28 Exhaust camshaft sprocket 29 Bolts 30 Intake camshaft 31 Timing chain 32 Bolts 33 Dowel sleeves A Positioning edge of crankcase Remove/Install Notes on self-locking nuts and bolts AH00.00-N-0001-01A 1 Remove air filter housing (1) together Remove air filter housing. AR09.10-P-1150PK
Page 3 of 10 with air recirculation flap actuator (2) Remove air recirculation flap actuator together with resonance body. AR09.50-P-8842PK 2 Remove top engine trim panels (3) 3 Remove cylinder head cover (4) AR01.20-P-5014PK 4 Take off air scoop (5) 5 Take off vacuum line (6) at electric vacuum pump (7) Inspect O-ring of air scoop, replace if necessary. Only models fitted with transmission 722.6. 6 Detach vacuum line (8) 7 Detach clamp (10) of exhaust gas recirculation at bracket (11) 8 Detach switchover valve (Y32) from bracket (11) 9 Detach bracket (11) from intake manifold 10 Take off dipstick guide tube (12) of automatic transmission at suspension eye Danger! Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. Press together the two clamps of the lock for this step and pull out vacuum line. Only models fitted with transmission 722.6. Detach two vacuum lines at switchover valve (Y32) for this step. Only transmission 722.6. No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. AS47.00-Z-0001-01A
Page 4 of 10 11 Remove fuel rail (13) together with injectors AR07.03-P-1450GS 12 Remove intake manifold (14) from the cylinder head Take off vacuum line (15) of purge valve Pull intake manifold away from cylinder head and attach in engine compartment with lines connected. Replace gaskets of intake manifold. Clean sealing surfaces. BA09.20-P-1001-01B 13 Detach crankcase ventilation pipe (16) at cylinder head 14 Detach engine ventilation lines Below flange connection of intake manifold/cylinder head. AR01.30-P-5800-06GS 15 Remove supercharger poly V-belt AR13.21-P-1202PK 16 Remove inlet and pressure connection (9) of compressor AR09.50-P-8841PK 17 Remove supercharger (17) AR09.50-P-4705PK 18 Remove lower engine compartment paneling Danger! 19 Drain coolant Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90 C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection. Drain coolant at crankcase. AR61.20-P-1105P AS20.00-Z-0001-01A AR20.00-P-1142PR Notes on coolant All engines AH20.00-N-2080-01A
Page 5 of 10 20 Disconnect front exhaust system (19) at exhaust manifold Replace screws (20). Inspect rivet nuts in exhaust manifold, replace if necessary. 21 Detach exhaust bracket (22) at transmission Replace rivet nuts in exhaust manifold. Attach exhaust system with cable straps. AR49.10-P-5531-01DA BA49.10-P-1005-01F BA49.10-P-1003-01F 22 Detach exhaust gas recirculation pipe (21) at crankcase Install new seals. 23 Take off fixtures of exhaust gas recirculation pipe (21) on right and left rear of cylinder head 24 Detach coolant line (23) of heater Push back clamp (24) until it locks in place; pull out coolant line. 25 Rotate engine at the crankshaft in direction of rotation until the piston of cylinder 1 is positioned at 20 after ignition TDC Inspect coolant line, replace if necessary. Replace seal of coolant line. The 20 marking on the belt pulley/vibration damper (25) must be aligned with the positioning edge (A) on the timing case cover. The cams of the exhaust camshaft and of the inlet camshaft at cylinder 1 must be pointing up at an angle. 26 Remove coolant thermostat housing AR20.10-P-2710PK
Page 6 of 10 27 Remove front cover at cylinder head AR01.30-P-5700PK 28 Mark camshaft sprockets relative to timing chain with a colored dot 29 Remove chain tensioner (18) AR05.10-P-7800PK 30 Remove top guide rail (26) Unscrew bolts (27). BA05.10-P-1003-01B 31 Remove exhaust camshaft sprocket (28) Counter-hold exhaust camshaft for slackening and attaching the bolts (29). 104 589 01 01 00 Replace bolts (29). BA05.20-P-1001-02A 32 Unbolt camshaft bearing caps of inlet camshaft (30) Tighten inlet camshaft bearing caps evenly (risk of fracturing). The camshaft bearing caps must be installed at the same point. BE05.20-P-1001-03A 33 Lift timing chain (31) off inlet camshaft sprocket 34 Remove inlet camshaft (30) Oil compensation elements and camshaft bearing points. The cams of the inlet camshaft must be pointing up at an angle at cylinder 1 after inserting the inlet camshaft (risk of fracturing). If necessary, inspect axial clearance of camshafts in fit bearing. Set basic position of exhaust BE05.20-P-1002-03A BE05.20-P-1003-03A AR05.20-P-6020GS
Page 7 of 10 camshaft/inlet camshaft. 35 Pull out guide rail pins of left guide rail Coat guide rail pins with sealant. Omnifit FD 3041 sealant. 36 Remove bolts (32) of cylinder head to timing case cover Replace bolts and moisten bolt head contact surface lightly with engine oil. AR01.30-P-5800-04GS BR00.45-Z-1014-01A BA01.40-P-1002-01G 37 Slacken cylinder head bolts in stages, unscrew Slacken cylinder head bolts in the reverse order of the tightening diagram once the engine has cooled down. Pay attention to tightening diagram of the cylinder head bolts. Lightly moisten thread and head contact surface of cylinder head bolts with engine oil. AR01.30-P-5800-01GS It is necessary to re-tighten the cylinder head bolts. BA01.30-P-1002-01B 38 Checking cylinder head bolts AR01.30-P-5800-03HA 39 Remove cylinder head Clean contact surfaces of cylinder head and of crankcase. Replace cylinder head gasket. Pay attention to the guide rails when fitting on the cylinder head. Pay attention to dowel sleeves (33) for
Page 8 of 10 40 Inspect contact surfaces of cylinder head and of crankcase for cracks and flatness 41 Blow out threaded holes of cylinder head bolts in crankcase with compressed air 42 Install in the reverse order Danger! Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near engine 43 Run engine and inspect for leaks locating the cylinder head. If necessary, machine cylinder head contact surface. Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts. AR01.30-P-7162GS AS00.00-Z-0005-01A 44 Inspect cooling system for leaks AR20.00-P-1010P 45 Read out fault memory and erase STAR Diagnosis Test values for camshaft bearings Number Designation Engine 111 BE05.20-P-1001-03A Diameter of camshaft bearing Standard size mm 28,00-28,02 Repair size mm 28,50-28,52 BE05.20-P-1002-03A Diameter of camshaft bearing journal Standard size mm 27,95-27,96 Repair size mm 28,45-28,46 BE05.20-P-1003-03A Axial clearance of camshaft in fit bearing mm 0,05-0,15 Cylinder head Number Designation Engine 111 BA01.30-P-1002-01B Cylinder head bolt M12 1st stage Nm 55 2nd stage 90
Page 9 of 10 Step 3 90 See picture in AR01.30-P- 5800-01A 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 Timing chain, chain tensioner Number Designation Engine 111 BA05.10-P-1003-01B Bolts at top of guide rail Nm 10 Camshaft, camshaft adjustment Number Designation Engine 111 BA05.20-P-1001-02A Bolt of camshaft sprocket/flange shaft 1st stage Nm 20 Step 2 60 BA05.20-P-1004-02A Bolt of camshaft bearing cap Nm 21 Intake manifold Number Designation Engine 111 BA09.20-P-1001-01B Bolts or nuts of intake manifold to cylinder head Nm 20 Exhaust system
Page 10 of 10 Number Designation Engine 111 in model 203 BA49.10-P-1003-01F Bolt of exhaust bracket to transmission Nm 20 BA49.10-P-1005-01F Bolt of flange connection to exhaust pipes or exhaust manifold Nm 20 104 589 01 01 00 Double open-end wrench Auxiliary repair materials Number Designation Order number BR00.45-Z-1014-01A Omnifit FD 3041 sealant (50 ml) 002 989 47 20 10