01-4150 Removing and installing cylinder head ‘Operation no. of operation texts and work units oF standard tes ‘nd nat cares: 01-B500-6885 A. Models 124, 129 with engine 104.98 tie RA OT.1216-415011B. Model 140 Ground cable at battery... 2... eee eee disconnect. connect, encada radin, model 140 normalize power windows. drain, pour in (20-0100, sivp 1). Piston of cylinder 1 Position to ignition TDC (step 2). Front cover at top. . seeseeeses — Fomova, install (01-2120), Timing chain with camshaft sprocket mark (stop 4). Pin (41) of guide rail. pull off, insert (step 5). Engine 104.98: . remove guide sprocket (2) (left-hand thread), install (@5 Nm, step 6). Coolant. ie AON. 1214-41502Armature (8) at camshaft adjuster Timing chain on camshaft sprockets Cable of position sensor at right wheelhouse... . Engine 104.98: : Tempomat eniso cont! inkage Engine 104.99: Vacuum lines at intake manifold Exhaust system at exhaust manifold . Engine 104.98: ...... Engine 104.99: .. . Bracket of dipstick guide tube (6a) and intake manifold support (6) Line of crankcase combination support Fuel flr cap (pressure) . Engine 104.98: admis Engine 104.99: .. . Hf automatic transmission fitted: . Bowden cable (aovelerator contro} : Control pressure cable ........ Coolant hoses and heating water return line (8). Cylinder head bolts (9) Cylinder head (10) ...... Oylinder head gasket (11) ..-..6e- see es Camshafts Piston of cylinder 1 Cylinder head bots (8) Cylinder head (10) Timing chain seis A 07,1214-415019 remove, install. take off, ft on take of, fit on (step 12). take off engine wi disconnect, connect. take off engine wiring hamess, ft on (step 12). take off, ft on (stop 13). unbott, bolt on. take off air injaction pipe (5) at cylinder head, fit ‘on (step 16), replace seal (6a). detach hase at non-return valve (Sb) of air injection pipe, fit on (stop 18). hamess, fi on (step 10). Uunbort, bolt on (step 17). take off, ft on (step 18). open, close (step 19) disconnect fuel pipes at fuel distributor, connect (step 19), disconnect fuel pipes at left wheelhouse, connect (step 19). Lunboit dipstick guide tube at cylinder head, bolt on (step 20). take off, fl on (step 21). take off, fit on (step 23). take off, fit on (step 24). Not model 140. elacken (etep 25). take off together with intake manifold and exhaust manifold (step 26). replace (step 28). A The cylinder head gasket is not watertight until tho ongine has reached operating temparature, in other words, until a swelling operation has taken place. For this reason, the cooling system must not be pressure-tested until after the engine nas reached operating temperature. position, secure (step 28), position to TDG (step 30). examine (01-4050). install, tighten (steps 31, 33, 34) fit on (step 25).Tightening torques in Nm or tightening angle Bolts for cylinder head cover 10 Bolts of camshaft bearing caps 21 1) Bolthead contact surface and thread oiled Special tools rc [& “ (116 689 01 34 00, 116 589 20 33 00 (104 589 00 4000 / (817 589 00 10 00 (007 689 72 21 00 (001 589 65 09 00 Note ‘Take off cylindar haad togethar with camshafts, intake manifold and exhaust manifold once ‘engine has cooled down. Seal secondary air injection hole on side right at cylinder heads for engines without secondary air injection hole with end cover part no. 104 016 00 33. wie RA OL.I214-415016Removing, Installing 1 Drain coolant at crankcase (20-0100). Disconnect coolant and heating hoses at cylinder head. 2 Position piston of cylinder 1 to ignition TDC. 3 Remove front cover at top (01-2120). 4 Mark position of camshaft sprockets to ming chain. To do this, apply coloured markings (arrows). 5 Pull off pin (1) for guide rail or friction rail with impact extractor 116 589 20 33 00 and threaded bolt 116 589 01 34 00. Installation note ‘The thread in the pin (1) must be located at the front (in direction of travel) when installed. Engine 104.98 Engine 106.99 sete RAOILI216-41505Engine 104.98 = 4 & —Unbolt guide eprockot (1) (left-hand thread) nec at Mf a\\ z ‘and take off together with bearing body (2). ©) i) { WS 7 Unbolt armature at camshaft adjuster. i » Wh “ig? Engine 104.98 8 Take timing chain off camshatt sprockets. 9 Unplug position sensor at right wheelhouse. Installation note ‘The connector must ba plugged in watertight. Engine 104.99 10 Take off engine wiring harness; to do this, slacken all the cable ties of the wiring hamess and unplug all the connectors. 11 Disconnect cruise control linkage. Engine 104,99 1. Unplug connactor at engine separation point 026/17). Unplug connector of electronic accelerator actuator (M16/1x1), press ratchet (arrow), ‘connector turns through 90° by means of a spiral spring Remove engine wiring harnesses from cable duct. Moge! 140 Ge AA OL. 1ee-41001013 Detach vacuum pipes at intake manifold {errow), fit on. Engine 104.99 14 Unscrew bolts for exhaust system at flange. of exhaust manifold, 18 Detach secondary air injection pipe (1) at the cylinder head, fit on. Replace seal. Engine 104.98 16 Detach hose at non-return valve of secondary air injection pipe (arrow), unbolt bracket (1). Engine 104.99 17 Unbolt bracket of dipstick guide tube and intake manifold support (arrows). Note regarding model 140 lemove dipstick guide tube. WER RAOLIZI-s150718 Detach pipe (43) of crankcase air admission at combination support (17). 19 Briefly open fual filer cap to release pressure in fuel tank, Unscrew fusl pipes (arrows). Countor-hold the connection fiting (1) when slackening the fuet pipe. Models 124, 129, Engine 104.98 Engine 104.09 20 f automatic transmission fitted, unbolt dipstick guide tube at reer of cylinder heed (arrow). wie RAOLIEN-LI50821 Detach Bowden cable (30) from the acealerator control levar (2). Compress plastic clip (28) and pull out Bowden cable. Installation note ‘Adjust Bowden cable (30-1010). 22 Detach control pressure cable (4), compress. plastic clip (6) and guide plastic clip with linkage through the bracket: Engine 104.98 Engine 108.99 24 Siacken hose straps at the coolant hose to, the coolant pump. Nemove heating water return pipe. 25 When engine cold, slacken cylinder head bolts in stages in the reverse order of the tightening diagram, beginning with 14. ip RAOT 1214-41509 OHSS Oe | CEE 126 Remove camshaft bearing caps 9 and 13. Install iting lugs, part no. 104 589 00 40 00. Lif off cylinder head with engine hoist and liting teckle, 27 Clean contact surface on crankcase and on oylinder head. 28 Replace cylinder head gasket. A ‘The cylinder head gasket is not watertight until the engine has reached operating temperature, in other words, until a swelling operation has taken place. For this reason, the cooling system must not be pressure-tested until after the engine has reached operating temperature. Cylinder head Engine 104.98 Engine 104.99 identification 104 016 16 20 104 016 17 20 b_ Mentication part no. © Wontfioaion rooca0e Engine 104.98, 2 recesses Engine 104.98, 9 recesses Siro 0: Engino 104.08 90.2 mm+0.5 Engine 103.99 90.9 mm+0.5 Installation note Pay attention to dowel pins for locating cylinder head on crankcase. 29 Rotate camshafts so that bottom edge of holes in camshaft flange form a level with top ‘edge of the cylinder head and check with 4 mm pins (1). wae AOI. 1214-4350/10830 Check TDC position of piston in cylinder 1 31. Fit on cylinder head with lifting tackle. 92 Examine cylinder head bolts (01~4050). 93. Oil the thread and the bolt head contact surface of the cylinder head bolts and insert. 24 Tighten cylinder head bolts in stages in the order of the tightening diagram, beginning with 1 (01-4080). 35 Fit on timing chain, pay attention to markings. 38 Remove pins from the camshatt flange. 87. Install in reverse order. iim RAOT IDIOT€. Models 202, 210 Preceding work: Front cover at top removed (01-2120). Resonance intake manifold top part removed (509.20-13100). ‘Operation no. of operation eas and work units or standard Texts and fiat rates: 01-5800 Front exhaust system (10) f secondary air injection fitted: Bracket (4) with spacer sleeve (6) al secondary air injection pipe (6) Coolant at crankcase f automatic transmission fitted: Coolant hose (9) at rear of cylinder head Position of camshaft sprockets relative to timing chain sie RADI A2M-A15012 Por seeT 7 unbott at exhaust manifold, bolt on. detach secondary air injaction hose (3), fit on tunbot, bott on. drain (20-1142). unbolt dipstick guide tube (8) at rear right of cylinder head, bolt on. take off, fi on. mark with coloured dots (arrows). Note Fit ming chain onto coloured markings (arrows).Exhaust camshaft sprocket (76) Timing chain of inlet camshaft sprocket Oylinder head boks (9) together First camshait bearing cap (13) of Bracket (3) 104 589 00 4000. Cylinder head contact surface or, POT-S8BE 7 unbolt, bolt on; tightening torques see (05-2180). take off. slacken when engine cold with screwdriver bit 617 569 00 10 00 in stages in reverse order of tightening diagram, beginning with 14, unserew. unbolt, bolt on (21 Ne). install in place of first camishaft bearing cap (13) with beering cap bolts (1a), bolt on (21 Nin). attach to bracket (3) and rear engine lifting point litt, remove. examine.Tapped holes clean. a Free of oil and water. Cylinder head gasket (11) 6... 2... eee replace. Note ‘The cylinder head gasket (11) for engine 104,941 is identified with three recesses (arrows). aA ‘The cylinder head gasket is not watertight until the engine has reached operating temperatura, in other words, until a swelling operation has taken place. For this reason, the cooling system must not be pressure-tested until after the engine has reached operating temperature, see install cee note, s+ees examine (01-4080), Cynder head (19)... eee eee Dowel sleeves (12) Cylinder head botts (9) Cylinder head botts (9) Cylinder head botts (9) Cylinder head bolts. - oil a thread and at bolt head contact surface. insert with washers (9a). <- +. tighten in stages in order of tightening diagram, boginning with 1 (01-4050). Special toole Wusrgea sear oa? Tier see cove 00) WT e0o ses or 1000 wii RAOT 1214-41506617 689 00 10 00 ‘Tightening torques In Nm or tightening angle Camshaft sprocket to camshaft Torx T40 500 05-2180 Bolts of camshaft bearing caps Torx T40 a1 Note ‘Take off cylinder head together with camshafts, intake manifold and exhaust manifold onca ‘engine has cooled down. Seal secondary air injection hole at right side on cylinder heads for engines without secondary air injection hole with end cover part no. 104 016 00 83. ett RA ON.1216-41505