AR01.30-P-5800PK
Remove/install cylinder head
ENGINES 111.955 in MODEL 203.045 /245 /745
ENGINES 111.981 in MODEL 203.747

16.10.09

P01.30-2081-09

12345689101112

Air cleaner housing
Resonance unit
Engine covers above
Cylinder head coverAir scoop
Vacuum line
Vacuum line
Inlet and pressure connection
ClipBracket
Oil dipstick guide tube

131415161718192021

Fuel distributor
Intake manifold
Vacuum line
Crankcase vent pipe
Compressor
Chain tensioner
Front exhaust system
Bolts
Exhaust gas recirculation tube

M56Y32

Vacuum pump brake booster
Air pump switchover valve

P01.30-2082-09

22232425

Exhaust bracket
Coolant line (cylinder head
Clamp
Vibration damper

heat exchanger)© Daimler AG, 8/7/24, L/10/16, ar01.30-p-5800pk, Remove/install cylinder head
ENGINES 111.955 in MODEL 203.045 /245 /745 ENGINES 111.981 in MODEL 203.747

29303132Bolts
Intake camshaft
Timing chain
Bolts
Page 1 of 6

262728

Top guide railBolts
Exhaust camshaft sprocket

33

Fitting sleeves

Apositioning edge on timing case cover

Remove/install
Notes on self-locking nuts and bolts
1

Remove air recirculation flap actuator

2
3
4

Remove engine covers above (3)Remove cylinder head cover (4)Remove air scoop (5)5Detach vacuum line (6) from brake booster
electric vacuum pump (M56)

AH00.00-N-0001-01A
Remove air recirculation flap actuator with AR09.50-P-8842PK
resonator (2).
AR01.20-P-5014PK
Installation: Install new O-ring.
Vehicles with transmission 722.6
To do this, press two clamps on the catch
together and pull out the vacuum line.

6

Detach vacuum line (8)Vehicles with transmission 722.6
Remove exhaust gas recirculation clamp (10)on bracket (11)Remove air pump switchover valve (Y32)
When doing this, detach the two vacuum
from bracket (11)lines from the switchover valve.

78
910Danger!

1112

Remove bracket (11) from intake manifold(14)Remove oil dipstick guide tube (12) fromVehicles with transmission 722.6
automatic transmission at lifting eye
Risk of explosion caused by fuel igniting,No fire, sparks, open flames or smoking.
AS47.00-Z-0001-01A
risk of poisoning caused by inhaling andPour fuels only into suitable and appropriatelyswallowing fuel and risk of injury to eyes and marked containers.
skin caused by contact with fuelWear protective clothing when handling fuel.
Remove fuel rail (13) together with injectors
AR07.03-P-1450GS
Detach intake manifold (14) from cylinder
Detach purge valve vacuum line (15).
head
Pull intake manifold from cylinder head and fix
in place in engine compartment together with
attached lines.
Installation: Clean the sealing surfaces;
replace the intake manifold seals.
*BA09.20-P-1001-01B

13

Remove crankcase vent pipe (16) on cylinder
head
Detach the crankcase ventilation hose1415
16
1718Danger!

Remove compressor (17) poly-V belt.
Remove intake and pressure connection (9)of compressor (17)Remove compressor (17)Remove bottom engine compartment
paneling
Risk of injury to skin and eyes caused byscalding from contact with hot coolant spray.
Risk of poisoning caused by swallowing
coolant.

Below flange connection for intake
manifold/cylinder head.

AR01.30-P-5800-06GS
AR13.21-P-1202PK
AR09.50-P-8841PK
AR09.50-P-4705PK
AR61.20-P-1105P

Do not open cooling system unless coolant
AS20.00-Z-0001-01Atemperature is below 90°C. Open cap slowly
and release the pressure. Do not pour coolant
into beverage containers.
Wear protective gloves, protective clothing
and safety glasses.
AR20.00-P-1142PR
Drain coolant at crankcase.

19

Drain coolant

20

Remove front exhaust system (19) on exhaust
Installation: Replace bolts (20).
manifold
Inspect rivet nuts in exhaust manifold, replace
if necessary.
Replace rivet nuts in exhaust manifold.
AR49.10-P-5531-01DA*BA49.10-P-1005-01F

21

Detach exhaust bracket (22) on transmission

Fasten exhaust system using cable ties.

22Remove exhaust return pipe (21) atcrankcase
Remove the LH and RH brackets of exhaustgas recirculation tube (21) at rear of cylinderhead
Remove coolant line (23) for heater

Installation: Replace sealing rings.

Notes on coolant

AH20.00-N-2080-01A*103589013900*BA49.10-P-1003-01F

2324© Daimler AG, 8/7/24, L/10/16, ar01.30-p-5800pk, Remove/install cylinder head
ENGINES 111.955 in MODEL 203.045 /245 /745 ENGINES 111.981 in MODEL 203.747

Press clip (24) back until it engages,remove coolant line.
Page 2 of 6Installation:
Inspect coolant line, replace if necessary.
Replace seal of coolant line.
25262728
293031

Turn the engine on the crankshaft center bolt
The 20° mark on belt pulley/ vibrationin the direction of engine rotation, until
damper (25) must be aligned with the guidecylinder 1 piston is at 20° after ignition TDC edge on the timing case cover (A).
The cams of the exhaust camshaft and of theinlet camshaft at cylinder 1 must be pointing
up at an angle.
Remove coolant temperature regulator
AR20.10-P-2710PK
housing
Remove front cover at cylinder head
AR01.30-P-5700PK
Marl camshaft sprocket to timing chain with acolor dot
Remove chain tensioner (18)AR05.10-P-7800PK
Unscrew bolts (27) and remove top slide rail
*BA05.10-P-1003-01B(26)
Remove exhaust camshaft sprocket (28)Counterhold bolts (29) for exhaustcamshaft when loosening and tightening.
*104589010100
Installation: Replace bolts (29).
*BA05.20-P-1001-02A

32

Unscrew camshaft bearing cap on intake
camshaft (30)Installation: Tighten the camshaft
bearing cover evenly (risk of breakage).
The camshaft bearing cover must be
reinstalled in the same position:*BE05.20-P-1001-03A

Marking of camshaft bearing caps

AH05.20-N-6992-01A*BA05.20-P-1004-02A

33
34

Lift timing chain (31) off intake camshaft
sprocket
Remove inlet camshaft (30)35Pull out slide rail bolt for left slide rail

Installation: Oil compensation elements *BE05.20-P-1002-03Aand 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, check the camshaft end play in *BE05.20-P-1003-03A
the fitted bearing.
Set basic position of exhaust/intake camshaft. AR05.20-P-6020GS
Installation: Coat the slide rail bolts with AR01.30-P-5800-04GS
sealant.
*116589203300*116589013400*605589003300

36

Sealant
Remove bolts (32) for cylinder head to timing
Installation: Replace bolts and wet bolt
case coverhead contact surface slightly with engine oil.

*BR00.45-Z-1012-01A*BA01.40-P-1002-01G
37

Slacken cylinder head bolts in stages andremove

Slacken cylinder head bolts in the reverse
order of the tightening procedure only onceengine has cooled down.
Installation: Observe tightening
procedure of cylinder head bolts.
Wet cylinder head bolts on thread and headcontact surface slightly with engine oil.

AR01.30-P-5800-01GS

It is not necessary to retighten the cylinder
head bolts.
*BA01.30-P-1002-01B
38

Check cylinder head bolts

39

Remove cylinder head40

Check the cylinder head and cylinder
crankcase contact surfaces for cracks andunevenness

41

Blow out threaded holes of cylinder head bolts
in crankcase with compressed air

AR01.30-P-5800-03HA*BE01.30-P-1001-04B
Installation: Clean contact surfaces ofcylinder head and crankcase.
Replace cylinder head gasket.
Pay attention to the slide rails when placing
the cylinder head.
Pay attention to dowel sleeves (33) for
locating the cylinder head.
If necessary:Face-machine cylinder head contact surface. AR01.30-P-7162GS© Daimler AG, 8/7/24, L/10/16, ar01.30-p-5800pk, Remove/install cylinder head
ENGINES 111.955 in MODEL 203.045 /245 /745 ENGINES 111.981 in MODEL 203.747

Page 3 of 642Danger!

434445

Install in the reverse order
Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving by
off by itself when engine is running. Risk ofitself.
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
Check for leaks with engine running
Inspecting cooling system for leaks
Read out the fault memory using STARDIAGNOSIS and clear it if necessary

AS00.00-Z-0005-01A

AR20.00-P-1010P

Check values for camshaft bearings
NumberDesignation

BE05.20-P-1001-03A

Camshaft bearing diameter

BE05.20-P-1002-03A

BE05.20-P-1003-03A

Engine 111

Diameter of camshaft bearing journalStandard sizemm

28.00 to 28.02

Repair stage

mm

28.50 to 28.52

Standard sizemm

27.95 to 27.96

Repair stage

mm

28.45 to 28.46mm

0.05 to 0.15

Axial clearance of camshaft in fit bearing

Cylinder head/cylinder head bolts
NumberDesignation

BE01.30-P-1001-04B

Cylinder headbolt

Engine111

Thread diameter

M

12Length (L) when newmm

102

Length (L)mm

105
AR01.30-P-5800-03HA

See picture

Cylinder head
NumberDesignation

BA01.30-P-1002-01B

Bolt, cylinder head

Engine 111

M12 Stage 1

Nm55

Stage 2°

90

Stage 3°90

See picture

AR01.30-P-5800-01A

Crankcase, timing case cover, end cover
NumberDesignation

BA01.40-P-1002-01GBolt, cylinder head to timing case cover© Daimler AG, 8/7/24, L/10/16, ar01.30-p-5800pk, Remove/install cylinder head
ENGINES 111.955 in MODEL 203.045 /245 /745 ENGINES 111.981 in MODEL 203.747

Engine111

Stage 1

Nm18Page 4 of 6

Stage 2°

90

Timing chain, chain tensioner
NumberDesignation

Engine111

BA05.10-P-1003-01B

Bolts for top of guide rail

Nm10

Camshaft, camshaft adjustment
NumberDesignation

Engine111

BA05.20-P-1001-02A

Bolt for camshaft sprocket/flangeshaft

Stage 1

Nm20

Stage 2°60

Bolt for camshaft bearing cap

Nm21

NumberDesignation

Engine111

BA09.20-P-1001-01B

Bolts and nuts, intake manifold tocylinder headBA05.20-P-1004-02A

Intake manifold

Nm

20

Exhaust system
NumberDesignation

Engine 111 inmodel 203

BA49.10-P-1003-01F

Bolt of exhaust bracket to transmission

Nm20

BA49.10-P-1005-01F

Bolt, flange connection to exhaust pipes or
exhaust manifold

Nm20

104 589 01 01 00

103 589 01 39 00

116 589 20 33 00

116 589 01 34 00

Open-end wrench, double

Caulking bolt

Impact extractor

Threaded stud

© Daimler AG, 8/7/24, L/10/16, ar01.30-p-5800pk, Remove/install cylinder head
ENGINES 111.955 in MODEL 203.045 /245 /745 ENGINES 111.981 in MODEL 203.747

Page 5 of 6

605 589 00 33 00
PullerRepair materials
Number
BR00.45-Z-1012-01A

Designation
Omnifit FD 3041 sealant© Daimler AG, 8/7/24, L/10/16, ar01.30-p-5800pk, Remove/install cylinder head
ENGINES 111.955 in MODEL 203.045 /245 /745 ENGINES 111.981 in MODEL 203.747

Order number
A 002 989 47 20 10

Page 6 of 6