AR01.30-P-5800BA Remove/install cylinder head 7.12.

05
ENGINE 112 in MODELS 170, 202, 208, 210, 220
ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475

P01.30-2092-09

Shown on model 220 with engine 112

1 Electric fan 10 Left ignition coils

2 Fan shroud 11 Generator
3 Poly-V-belt 12 Chain tensioner
4 Air filter housing 13 Intake manifold
5 Resonance tube 14 Camshaft position sensor
6 Resonance unit 15 Coolant line
7 Right cylinder head cover 16 Camshaft sprockets
8 Right ignition coils 17 Camshaft bearing bridges
9 Left cylinder head cover 18 Oil filter housing with oil-water heat exchanger

20 Bolts cylinder head timing case cover

21 Cylinder head bolts M11 141.5
22 Left cylinder head
23 Right cylinder head
24 Left cylinder head gasket
25 Right cylinder head gasket
26 Dowel sleeves

P01.30-0299-06

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 1/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
Remove/install
Danger! Risk of explosion caused by oxyhydrogen No fire, sparks, open flames or smoking. Wear AS54.10-Z-0001-01A
gas. Risk of poisoning and caustic burns acid-resistant gloves, clothing and safety
caused by swallowing battery acid. Risk of glasses. Only pour battery acid into suitable
injury caused by burns to skin and eyes from and appropriately marked containers.
battery acid or when handling damaged lead-
acid batteries
1 Disconnect battery ground cable Models 170, 202, 208, 210 AR54.10-P-0003A
Model 211.076 AR54.10-P-0003T
Model 211.276 AR54.10-P-0003TA
Model 215, 220 AR54.10-P-0003I
Model 230.474/475 AR54.10-P-0003R
Notes on battery All models AH54.10-P-0001-01A
Turn key in electronic ignition switch EIS
into position "0". Key cannot be withdrawn.
Vehicle with Keyless Go code 889:
Switch off engine, remove Keyless Go cards
from the vehicle and keep outside the range of
the transmitter.
Installation: After connecting, read out
fault memory, set the time in the instrument
cluster, code radio, normalize power windows
and tilting/sliding roof and activate steering
angle sensor.
Vehicles with stationary heater: Adjust the
time on the stationary heater control.
2 Remove engine compartment paneling Model 202, 208, 210 AR61.20-P-1105AB
Model 170 AR61.20-P-1105A
Model 211 AR61.20-P-1105T
Model 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
Danger! Risk of injury to skin and eyes caused by 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 containers.
Wear protective gloves, protective clothing and
safety glasses.
3 Drain coolant Engine 112 in models 202, 208, 210, 220, AR20.00-P-1142HA
Engine 113 (except 113.991) in Model 220,
Engine 113.963 in model 230.475
Engine 112 in Model 170 AR20.00-P-1142SV
Engine 113.990 in model 211.076/276, AR20.00-P-1142RVK
Engine 113.991 in models 215.374,
220.074/174/874
Engine 113.992 in model 230.474
4.1 Remove engine trim panel with integrated air Model 170.465,
filter Models 202, 208, 210,
Model 220 except 220.074/174,
Model 230.475
Unclip cover on front end of engine.
4.2 Remove air filter Model 170.466 AR09.10-P-1150SVK
Model 211.076/276,
Models 215.374, 220.074/174,
Model 230.474
5.1 Remove fan shroud (2) with electric fan (1) Before removing the fan shroud (2),
disconnect connector for electric fan (1).
Model 211 AR20.40-P-6800TC
Model 215, 220, 230 AR20.40-P-6800AB
6.1 Remove resonance tube (5) and resonance In the process separate the connector of
unit (6) the hot film mass air flow sensor and unscrew
the resonance pipe (5) on the cylinder head
cover.
The resonance pipe (5) is fastened to the
back of the intake manifold (13) with a plastic
strap.
Do not damage the plastic strap.
Engine 112.910 in models 202.026/086, AR07.07-P-1454A
Engine 112.920 in models 202.029/089,
Engine 112.911 in models 210.061/261,
Engine 112.921 in model 210.063/263/
081/281/663,
Engine 112.941 in model 210.065/082/
265/282,
Engine 112.940 in model 208.365/465

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 2/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
7.1 Remove hot film mass air flow sensor Engine 112.947 in model 170.465 AR07.07-P-1454AG
Engine 112.922 in model 220.063, AR07.07-P-1454AA
Engine 112.944 in models 220.065/165,
Engine 112.972 in models 220.067/167,
Engine 112.975 in models 220.087/187,
Engine 113.941 in models 220.070/170,
Engine 113.948 in models 220.083/183,
Engine 113.960 in models 220.075/175,
Engine 113.963 in model 230.475,
Engine 113.966 in model 220.084/184
Danger! Risk of explosion caused by ignition of No fire, sparks, open flames or smoking. AS47.00-Z-0001-01A
flammable products, risk of poisoning Pour fuels only into suitable and appropriately
caused by inhaling fuel vapors or swallowing marked containers.
fuel as well as risk of injury to skin and eyes
exposed to fuel. Wear protective clothing when handling fuel.
8 Disconnect fuel line at fuel rail Release fuel pressure through service
valve!
Collect fuel!
Engine 112
*BA07.52-P-1001-01A
Engine 113
*BA07.52-P-1001-01A
Pressure hose *119589046300
9 Remove right ignition coils (8) and left ignition Engine 112.910 in models 202.086/026, AR15.12-P-2003A
coils (10) Engine 112.920 in models 202.029/089,
Engine 112.921 in model 210.063/081/
263/281,
Engine 112.922 in model 220.063,
Engine 112.940 in models 208.465/365,
Engine 112.941 in model 210.265/065/
082/282,
Engine 112.944 in models 220.065/165,
Engine 113.940 in models 210.070/270,
Engine 113.941 in models 220.070/170,
Engine 113.960 in models 215.375, 220.175
/075/875,
Engine 113.943 in models 208.470/370,
Engine 113.984 in model 208.374,
Engine 112.947 in model 170.465,
Engine 112.960 in model 170.466,
Engine 113.986 in model 220.173, 215.373,
220.073,
Engine 113.963 in model 230.475,
Engine 112.913 in models 211.061/261,
Engine 112.949 in models 211.065/265,
Engine 113.967 in model 211.070,
Engine 113.992 in model 230.474,
Engine 113.990 in model 211.076/276,
Engine 113.991 in models 220.174/074,
215.374
Engine 112.972 in models 220.167/067,
Engine 112.973 in model 230.467,
Engine 112.975 in models 220.087/187,
Engine 113.948 in models 220.083/183,
Engine 113.966 in model 220.084/184
10 Remove right cylinder head cover (7) and left Engines 112, 113 air filter located on vehicle AR01.20-P-5014B
cylinder head cover (9) side
Engines 112, 113 air filter located on engine AR01.20-P-5014BV
side
11.1 Remove compressor Model 170.466, 211.076/276, 215.374, AR09.50-P-4705SVK
220.074/174, 230.474
11.2 Remove intake manifold (13) Except models 170.466, 211.076/276, AR09.20-P-1310A
215.374, 220.074/174, 230.474
Remove intake manifold (13) together with
fuel distributor.
The intake manifold system must not be
disassembled.
Installation: On vehicles with engine
damage the intake manifold (13) must be
examined for shavings prior to assembly and
any shavings removed, otherwise the next
engine damage would be preprogrammed.
12.1 Remove camshaft position sensor (14) Only necessary when removing the right
cylinder head (23).
Engine 112 in Model 170, 202, 208, 210, 220, AR15.10-P-2000A
Engine 113 (except 113.991) in Model 220,
230.474/475
Engine 113 in Model 211.076/276, 215.374, AR15.10-P-2000RVK
220.074/174

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 3/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
13.1 Unbolt dipstick guide tube from bracket at Model 211, 215, 220.074/174, 230.474/475
cylinder head
14 Remove poly-V-belt (3) Installation: Lock tensioning device with a
drift or pin (diameter 5 mm).
Engine 112 in Model 170 AR13.22-P-1202SV
Engine 112 in Model 202, 208.365/465, 210, AR13.22-P-1202BA
220.063/065/067/087/165/167/187,
Engine 113 in models 220.070/073/075/083
/084/170/173/175/183/184/875
Engine 113 in model 211.076/276 AR13.22-P-1202RV
Engine 113 in models 215.374, 220.074/174, AR13.22-P-1202R
230.474/475
15 Detach coolant line (15) from left cylinder head On models 202.093/033 an additional
(22) coolant line is attached to the right cylinder
head (23). The coolant line of the right cylinder
head (23) leads to an external transmission oil
cooler, the right is located behind the front
apron.
6 mm socket hexagon *WH58.30-Z-1001-06A
7 mm socket hexagon *WH58.30-Z-1002-06A
16 Detach exhaust system at exhaust manifold Installation: On vehicles with engine
damage the exhaust system must be
examined for swarf and any swarf present
removed before installing. Otherwise the
catalytic converter would be damaged.
Engine 112.915 in model 202
Engine 112.911/914 in model 210
Engine 112 in model 170 AR49.10-P-7000SV
Engine 112.910 in models 202.026/086, AR49.10-P-7000AU
Engine 112.920 in models 202.029/089,
Engine 112.940 in model 208.365/465
Engine 112.921/941 in model 210 AR49.10-P-7000A
Engine 112 in model 220, AR49.10-P-7000AA
Engine 113 in model 215.374, 220
Engine 113 in model 211.076/276 AR49.10-P-7000TB
Engine 113 in model 230.474 AR49.10-P-7000RA
Engine 113 in model 230.475 AR49.10-P-7000R
*BA14.10-P-1002-01B
17 Position crankshaft at a 40° crank angle after The engine must not be turned back, AR05.10-P-6858V
ignition TDC of cylinder 1 otherwise the timing chain may skip a tooth.
Rotate engine at crankshaft in direction of
rotation until 40° marking on belt pulley/
vibration damper is aligned with marking on
timing case cover.
The grooves on the camshafts must be
pointing toward the inner V.
If there are no adjusting marks on the
camshafts, locating plates are used to adjust
the timing.
Locating plate *112589003200
Locating plate *112589013200
18 Lock camshafts with locating plate Locating plate *112589003200
Locating plate *112589013200
19.1 Remove oil/water heat exchanger at oil filter Engine 112 in Model 170, 202, 208, 210, 220, AR18.30-P-3481CA
Engine 113 in model 220,
Engine 113.963 in model 230.475
20 Remove oil filter housing Engine 113.990 in model 211.076/276, AR18.20-P-3471RKV
Engine 113.991 in models 215.374, 220.074
/174,
Engine 113.992 in model 230.474
Engine 112 in Model 170, 202, 208, 210, 220, AR18.20-P-3471BA
Engine 113 (except 113.991) in Model 220,
Engine 113.963 in model 230.475
21 Remove chain tensioner (12) Engine 112 in models 170, 202, 208, 210, AR05.10-P-7800CA
Engine 112 in model 220, AR05.10-P-7800AM
Engine 113 in models 211, 215, 220, 230
22 Remove camshaft sprockets (16) When the camshaft sprockets (16) are
removed the engine must not be cranked any
more, otherwise the timing chain could be
canted over.
Right-hand camshaft sprocket:
Tie timing chain tight on camshaft sprocket
with cable 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.
*BA05.20-P-1001-01B

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 4/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
Open-end wrench *112589000100
Insertion tool *112589010300
Torque wrench *001589722100
After installation:
Check basic position of camshafts AR05.10-P-6858V
After inspecting, if necessary:
Set the basic position of camshafts AR05.20-P-6020AU
23 Remove camshaft bearing bridges (17) Engines 112, 113 except engine 113.960 with AR05.20-P-7103AU
cylinder shutoff, code 479
Engine 113.960 with cylinder shutoff code 479
AR05.20-P-7103AV
24 Unscrew bolts, cylinder head timing case *BA01.40-P-1002-01C
cover (20)
25.1 Take off locating plates and remove camshafts Models 211, 215, 230.474/475
26 Slacken cylinder head bolts M11 141.5 (21) in Slacken cylinder head bolts M11 141.5 (21) AR01.30-P-5800-09B
stages, unscrew according to loosening pattern on a cooled off
engine. The cylinder head bolts M11 141.5
(21) would be overstretched otherwise .
Installation: Observe tightening pattern AR01.30-P-5800-07B
and tightening instructions of cylinder head
bolts M11 141.5 (21). Oil cylinder head bolts
M11 141.5 (21) at thread and bolt head
contact surface.
*BA01.30-P-1001-01D
Screwdriver insert *000589031000
27 Remove cylinder head
Information on applying sealant to cylinder Engine 113 AH01.30-P-1000-04V
head gasket
Information on applying sealant to cylinder Engine 112 AH01.30-P-1000-04VA
head gasket
Information on cylinder head contact surface AH01.30-P-1000-05A
Installation: On engine 113 due to porous
points in the left cylinder head, sealing
compound must be coated on the left cylinder
head gasket, otherwise there would be leaks
at the left cylinder bank.
Installation: Observe dowel sleeves (26)
for locating the cylinder head, otherwise the
cylinder head would cant over.
Installation: The sealing compound must
be processed within 10 minutes.
Sealant *BR00.45-Z-1013-01A
Checking
28 Inspect version of cylinder head gasket
Information for assigning the cylinder head AH01.30-P-1000-06V
gaskets
29 Inspect cylinder head bolts M11 141.5 (21) AR01.30-P-5800-03B
*BE01.30-P-1001-04B
30 Clean, check sealing surfaces and tapped Check for cracks, blowhole inclusions,
holes unevenness and damage.

Sealing surfaces of crankcase and cylinder

head are provided with an 0.8 mm thick
silicone layer during series production.
Silicone sealant is applied in the gasket area
when carrying out repairs only if shrink holes
are present.
Installation: The sealing compound must
be processed within 10 minutes.
Sealant *BR00.45-Z-1013-01A
31 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 grasp hot or rotating parts.
running engine
32 Run engine and inspect for leaks
33 Inspect cooling system for leaks Warm up engine to operating temperature
and then inspect cooling system or leaks.
Engine 112 (except 112.947/960) in Model AR20.00-P-1010HA
202, 208, 210, 220,
Engine 113 (except 113.991) in Model 220
Engine 113.992 in model 230.474, AR20.00-P-1010RVK
Engine 113.990 in model 211.076/276,
Engine 113.991 in model 215.374,
Engine 113.991 in models 220.074/174,
Engine 113.963 in model 230.475

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 5/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
Engine 112.947 in model 170.465, AR20.00-P-1010P
Engine 112.960 in model 170.466
34 Read out fault memory and erase When the work is complete stored faults
must be worked on in the diagnostic trouble
code memories and erased.
The stored faults may be caused by lines
removed during assembly or during test work
and by a simulation.
Connect STAR DIAGNOSIS and read out fault AD00.00-P-2000-04A
memory
35 Carry out function check

Cylinder head/cylinder head bolts

Number Designation Engine Engines

112.910/911/ 113.940/941/
912/913/914/ 942/943/944/
915/916/917/ 945/946/948/
920/921/922/ 960/961/962/
963/964/965/
923/940/941/
966/967/968/
942/943/944/
969/971/980/
945/946/947/
949/951/953/ 981/982/984/

954/955/960/ 986/987/988/
990/991/992/
961/970/972/
993/995
973/975/976

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 144.5 144.5

See picture
AR01.30-P-5800-03 AR01.30-P-5800-0
B 3B

Cylinder head

Number Designation Engine Engine

113.987/ 113.990/
988 991/992/
993/995

BA01.30-P-1001-01D Bolt, cylinder head to Stage 1 Nm 10 10

crankcase
Stage 2 Nm 30 30

Stage 3 ° 90 90

Stage 4 ° 90 90

BA01.30-P-1002-01D Bolt of chain housing M8 Nm - -

Cylinder head

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 6/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
Number Designation Engine Engines
112.910/911/ 113.940/941/
912/913/914/ 942/943/944/
915/916/917/ 948/960/961/
920/921/922/ 962/963/965/
923/940/941/ 966/967/968/
942/943/944/ 969/971/980/
945/946/947/ 981/982/984/
949/951/953/ 986
954/955/960/
961/970/972/
973/975/976

BA01.30-P-1001-01D Bolt, cylinder head to Stage 1 Nm 10 10

crankcase
Stage 2 Nm 30 30
Stage 3 ° 90 90

Stage 4 ° 90 90

Crankcase, timing case cover, end cover

Number Designation Engine Engine

112 except 112.951/
112.951/ 976
976

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

Crankcase, timing case cover, end cover

Number Designation Engines Engine

113.940/941/ 113.987/
942/943/944/ 988/990/
945/946/948/ 991/993
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995

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

Camshaft

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 7/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
Number Designation Engines
113.940/941/
942/943/944/
948/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995

BA05.20-P-1001-01B Bolt, camshaft sprocket M12 45 Stage 1 Nm 50

Stage 2 ° 90

Camshaft

Number Designation Engine Engine

112 112.951/
except 976
112.951/976

BA05.20-P-1001-01B Bolt, camshaft sprocket M12 45 Stage 1 Nm 50 50

Stage 2 ° 90 90

Camshaft

Number Designation Engine Engine

113.960 with 113.987/988/
code 479 990/993

BA05.20-P-1001-01B Bolt, camshaft sprocket M12 45 Stage 1 Nm 50 50

Stage 2 ° 90 90

Camshaft

Number Designation Engine

113.991

BA05.20-P-1001-01B Bolt, camshaft sprocket M12 45 Stage 1 Nm 50

Stage 2 ° 90

Fuel rail

Number Designation Engine Engine

112 except 112.960/
961 AMG
112.945/
951/960/
961

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ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
BA07.52-P-1001-01A Disconnect fuel feed line at fuel rail Nm 38 35

Fuel rail

Number Designation Engine Engines Engine Engines

113.987 113.990/ 113.992/ 113.940/941/
991 993/995
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/988

BA07.52-P-1001-01A Disconnect fuel feed line at fuel rail Nm 38 38 38 38

Exhaust manifold

Number Designation Engine Engines Engines

112 except 113.940/941/ 113.987/
112.951/ 942/943/944/ 988/990/
945/946/948/
976 991
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/993/
995

BA14.10-P-1002-01B Flange connection, exhaust manifold and front Nm 20 20 20

exhaust pipes

001 589 72 21 00 119 589 04 63 00 112 589 00 32 00 112 589 01 32 00

Torque wrench Pressure hose Locating plate Locating plate

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

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 9/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475
Open end wrench Insertion tool Screwdriver insert

Commercially available tools

Number Designation
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive

Repair materials

Number Designation Order number

BR00.45-Z-1013-01A Sealant A 003 989 98 20

© Daimler AG, 5/13/13, G/10/08 / ar01.30-p-5800ba / Remove/install cylinder head Page 10/10
ENGINE 112 in MODELS 170, 202, 208, 210, 220 ENGINE 113 in MODELS 211.076 /276, 215.374, 220, 230.474 /475