Removal and Replacement
Preceding work:
- Coolant: drained. Cooling System
- Cylinder head covers: removed. Service and Repair
Procedure:
NOTE: Every step below applies regardless of which side you are removing, unless stated otherwise within a specific step.
- Remove intake manifold.
- Remove front cover at top at cylinder head to be removed. Service and Repair
- Remove guide rail of cylinder head at cylinder head to be removed. Service and Repair
- Remove camshaft adjuster at cylinder head to be removed. Service and Repair
- Left cylinder head: Unscrew bolts (1). (1a) and (2).
Tighten to: (21 Nm).
- Place retaining plate to the side with power steering pump (11) and oil lines connected.
Installation Note: Coat bolt (2) with sealant 002 989 47 20 10.
Engine 119.97x: install bolt (1a) with retaining bracket (4) of wiring harness.
- Right cylinder head: Unbolt engine oil dipstick tube (22).
- Remove guide rail (23) for ignition cables.
- Right cylinder head: Unbolt transmission oil dipstick tube (12) (Automatic Transmission).
- Unbolt front exhaust system at exhaust manifold. Exhaust System
Right Cylinder Head:
Left Cylinder Head:
- Right-hand cylinder head: Unscrew fitted collar bolts or bolts + washers (a) and (b) to timing case cover.
Tighten to: (25 Nm).
NOTE: When performing repairs, install fit collar bolts or the bolts + washers depending on the bolts used previously.
- Left-hand cylinder head: Unscrew bolts (d) and (e) to timing case cover.
Tighten to: (25 Nm).
- Loosen cylinder head bolts when engine is cold with screwdriver bit in stages in reverse order of tightening diagram shown in images above, beginning with 10. Remove bolts.
Use special tool 119 589 00 10 00.
NOTE:
- Models 124, 140: cylinder head bolt 10 cannot be removed with cylinder head installed; for this reason, raise and secure.
- Model 210: cylinder head bolts 9 and 10 of both cylinder heads cannot be removed with cylinder head installed; for this reason, raise and secure.
- On "closed-deck" crankcases, the cylinder head bolts installed have different length, refer to bolt diagram.
- Loosen first and fourth camshaft bearing caps (18) of inlet camshaft.
- Bolt bracket (17) on with bearing cap bolts and dowel sleeves (18a) instead of first and fourth camshaft bearing caps (18). Use special tool 119 589 0140 00.
- Attach engine hoist to bracket (17).
- Raise and remove cylinder heads (13) and (14).
- Examine cylinder head contact surface. Checking/Refacing Cylinder Head Contact Surface
- Clean tapped holes of cylinder head bolts.
CAUTION: Ensure holes are free of oil and water.
- Replace cylinder head gaskets (19) and (20).
CAUTION: The cylinder head gasket is not watertight until the engine has reached normal operating temperature, in other words until a swelling process has taken place. For this reason, the cooling system must not be pressure-tested until after the engine has reached normal operating temperature.
- Install cylinder heads (13) and (14).
- Note dowel sleeves (f) or roll pins (c).
- Examine cylinder head bolts (15).
NOTE: The cylinder head bolts (15) are subjected to a certain permanent stretch each time they are tightened. If the maximum length is exceeded (see table below), the bolts should be replaced with new ones.
- Oil cylinder head bolts (15) at thread and at contact surface of bolt head.
- Insert cylinder head bolts (15) with washers (15a).
- Tighten cylinder head bolts in stages, in sequence of tightening diagram, beginning with 1.
Tightening torques see table below.
- Complete assembly in reverse of removal procedure. Observe all tightening specifications within this article and all installation notes.
Cylinder Head Bolt Tables
Cylinder Head Bolt (12-pt Socket with "Closed-Deck")
Thread Diameter "D" 12 mm
Stretch Shank Diameter "d":
When New 10.75 ± 0.05 mm
Thread Length "a" 135 mm
Bolt Length "L":
When New 160 ± 0.8 mm
Maximum Bolt Length 162.70 mm
Cylinder Head Bolt (12-pt Socket with "Open-Deck")
Thread Diameter "D" 12 mm
Stretch Shank Diameter "d":
When New 10.75 ± 0.05 mm
Thread Length "a":
Short Bolt 135 mm
Long Bolt 190 mm
Bolt Length "L":
When New:
Short Bolt 160 ± 0.8 mm
Long Bolt 218 ± 0.9 mm
Maximum Bolt Length:
Short Bolt 162.70 mm
Long Bolt 221.60 mm
Tightening Torques And Tightening Angle Table
Cylinder head bolts, engine cold*
1st stage: 55 Nm
2nd stage: 90° tightening angle
3rd stage: 90° tightening angle
Bolts of camshaft bearing caps M7: 15 Nm
Bolts of cylinder head timing case cover M8: 25 Nm
* Moisten washers and thread and contact surface of bolts with oil before installing.
Bolt Diagram:
"Closed-Deck" Cylinder Head Bolts Numbers 1 to 10 = M12 x 160 mm
"Open-Deck" Cylinder Head Bolts:
Numbers: 1, 3 and 5 = M12 x 218 mm
Numbers: 2, 4, 6, 7, 8, 9, 10 = M12 x 160 mm
NOTE: Cylinder head bolts: Cylinder head bolts match with washers. "Closed-Deck" cylinder head bolts are phosphatized, washers chrome-plated. "Open-Deck" cylinder head bolts are chrome plated, washers are phosphatized.
No "HELI-COIL inserts are installed in crankcase of "open-deck version. HELI-COIL inserts may be used when performing repairs.