01—415 Removal and installation of cylinder head
 
 

 
 
Timing at 2 mm valve lift
Engine 110            Engine 110            Engine 110
California 1974            Federal
1973 and 1974
 
 

 
 
Exhaust
24,57,71,78 24
30,95
 
 
Camshaft code number
 
 

 
 
Intake
25. 67. 74
25, 74
33, 91
 
 

 
 
opens after TDC
11°
 
 

 
 
Intake valve
 
 

 
 
closes after BDC
21
o
15°
 
 

 
 
Exhaust valve
opens before BDC
30°
22°
 
 

 
 
closes before TDC
 
 

 
 
) The camshaft code number is punched into rear end of camshaft.
 
 

 
 
                   
 
Valve clearance
on cold engine
(approx.
20 °C)
on warm
engine
(60°C ±
15°C)
 
 
Intake
0.10')


0.15')



 
 
Exhaust
0.25


0.30



 
                   
 
 

 
 
1 ) 0.05 mm larger during lasting outside temperatures below —20°C.
 
 

 
 
Tightening torques
Nm
 
 

 
 
Bolts and cap nuts for cylinder head cover
 
 

 
 
Necked-down screw for camshaft sprockets
80
 
 

 
 
step 1
40
 
 

 
 
Cylinder head bolts M 12 x 1.5 on cold engine
 
 

 
 
step 2
70
 
 

 
 
       
 

after 10 min. setting time 110
 
 
Bolts M 8 for cylinder head to crankcase
25
 
 
Closing plug chain tensioner
50
 
 
Threaded ring chain tensioner
50
 
 
Ball seat ring in chain tensioner
25
 
 
Special tools

 
       
 
 

 
 
Remover and installer for rocker arm
m110 - 0046-1.jpg
110 589 04 61 00
 
 

 
 
01.2-415/1 F3
 
 

 
                   

 

 

     
 

 
 
m110 - 0047-1.jpg
 
 

 
 
Note
 
 

 
 
A cylinder head may only be removed after the engine is cold. Removal is together with the camshaft housing, exhaust manifold and intake manifold.
 
 

 
 
01.2-415/2 F3
 
 

 
     

 

       
 

 
 
There is only one type of cylinder head as a replace­ment part for carburetor and fuel injection engines.
If the cylinder head is used on a carburetor engine, the fuel injector bores must be plugged with 6 covers, part number 000 443 01 80 00.
Starting April 1978 exhaust valve seat rings 42 mm OD and valve guides 9 mm ID are installed in cylinder head. Exception: engines national version.
m110 - 0048-1.jpg
 
 

 
 
Cylinder heads for engines with air injection are attached to exhaust ducts by means of threaded bores for air injection.
The diameter of the combustion chamber frame on cylinder head gaskets for the various repair stages varies:
m110 - 0048-2.jpg
 
 
         
 
Cylinder bore
Combustion
chamber frame
 
 
86.00 0 86.50 0
86.70+ 0.5
mm 0
 
 
87.00 0
87.20 + 0.5
mm 0
 
 
Removal


 
         
 
 
m110 - 0048-3.jpg
 
 
1 Remove compressor of models with an air condi­tioner.
 
 

 
 
2 Remove oil pump of models with a level control system and place it to one side without undoing the lines. Only unscrew the bolts marked with an arrow for this purpose.
m110 - 0048-4.jpg
 
 

 
 
01.2-415/3 F3
 
 

 
       

 

 

       
 

 
 
3 Remove vacuum pump of models for USA.
m110 - 0049-1.jpg
 
 

 
 
4 Drain coolant from radiator and engine.
m110 - 0049-2.jpg
 
 
Model 123
 
 

 
 
5 Unscrew both covers at front of camshaft housing.
m110 - 0049-3.jpg
 
 

 
 
6 Disconnect all electric wires, heater water, fuel and vacuum lines which are connected to the cylinder head and intake manifold or carburetor.
 
 

 
 
01.2-415/4 F3
 
 

 
       

 

       
 

 
 
7 Remove longitudinal regulating shaft (3).
m110 - 0050-1.jpg
 
 

 
 
8 Disconnect oil return pipe at cylinder head.
m110 - 0050-2.jpg
 
 

 
 
9 Remove hose between thermostat housing and water pump.
Disconnect bypass line at water pump.
m110 - 0050-3.jpg
 
 

 
 
10 Disconnect oil dipstick guide tube from clamp on cylinder head and bend to one side.
 
 

 
 
01.2-415/5 F3
 
 

 
       

 

       
 

 
 
11 Detach exhaust pipe at exhaust manifold and trans­mission. Unscrew pre-heating cowl of models with car­buretor engines.
 
 

 
 
12 Press out all spring clamps with a wrench socket.
m110 - 0051-1.jpg
 
 

 
 
13 Remove all rocker arms with the remover and installer (05-230).
m110 - 0051-2.jpg
'419
 
 

 
 
14 Turn crankshaft with combination tool.
 
 

 
 
Attention!
Don't turn engine on camshafts. Don't turn engine in
reverse direction of rotation.
m110 - 0051-3.jpg
 
 

 
 
HOO-6498/1
 
 

 
 
01.2-415/6 F3
 
 

 
       

 

       
 

 
 
15 Position 1st cylinder of engine at ignition TDC. Marks on camshaft sprockets and camshaft housing must align.
m110 - 0052-1.jpg
 
 

 
 
m110 - 0052-2.jpg
 
 

 
 
16 Remove both expansion bolts of camshaft sprock­ets. Counterhold camshaft with holder.
m110 - 0052-3.jpg
 
 

 
 
17 Remove upper slide rail in camshaft housing (05-340).
Knock out bearing pins with the impact extractor for this purpose.
m110 - 0052-4.jpg
 
 

 
 
01.2-415/7 F3
 
 

 
       

 

       
 

 
 
18    Remove chain tensioner (05—310).
19   Push both camshafts to the rear and remove camshaft sprockets.
m110 - 0053-1.jpg
 
 

 
 
20 Remove guide wheel. Knock out bearing pins with impact extractor (M 10 bolts) for this purpose.
m110 - 0053-2.jpg
 
 

 
 
21 Remove guide rail in cylinder head. Knock out bearing pins with impact extractor (6 x 150 mm bolt) for this purpose.
m110 - 0053-3.jpg
 
 

 
 
22 Loosen and remove cylinder head bolts in reverse sequence of tightening diagram. Pull out the two M 8 bolts in the timing case with a magnet.
m110 - 0053-4.jpg
 
 

 
 
01.2-415/8 F3
 
 

 
       

 

       
 

 
 
23 Pull up timing chain and press tensioning rail to center of engine. Lift off cylinder head straight up with a cable attached to the suspension eyes.
 
 

 
 
Installation
 
 

 
 
24   Clean cylinder head and crankcase mating surfaces thoroughly.
25    Install new cylinder head gasket.
Note: Two dowel sleeves are press-fit in the crankcase to locate the cylinder head.
 
 

 
 
26    Place two locally manufactured wooden boards
(15 x 35 x 240 mm) on the cylinder head gasket, front upright and rear flat.
27    Place cylinder head on board, guide in timing chain and tensioning rail.
28    Lift front of cylinder head and pull out front wooden board toward exhaust side. Lower cylinder head until it fits on the dowel sleeve.
29    Lift rear of cylinder head slightly and pull out wooden board toward exhaust side. Lower cylinder head until it fits over rear dowel sleeve.
Note: If possible, connect cylinder head with cam­shaft housing to eyes for engine removal, carefully lower with a crane and set down.
m110 - 0054-1.jpg
 
 

 
 
01.2-415/9 F3
 
 

 
       

 

       
 

 
 
30 Lubricate threads and head surface of cylinder head bolts before installation.
Attention!
Since July of 1974 the clearance on the camshaft housing for the 22 mm dia. washer of cylinder head bolt number 14 has been extended. The former 20 mm dia. washer must be installed on older camshaft hous­ings (arrow).
m110 - 0055-1.jpg
 
 

 
 
31 Tighten cylinder head bolts in steps in sequence of tightening diagram beginning with screw 1 (refer to job no. 01—415 removal and installation of cylinder head).
Tighten screws M 8 to 25 Nm (2.5 kpm).
m110 - 0055-2.jpg
 
 

 
 
Attention!
After all bolts have been tightened, it must be possible to turn both camshafts by hand.
 
 

 
 
32    Install slide rail (2a). For this purpose, pull up timing chain while introducing slide rail with pliers and knocking-in bearing bolts with impact puller. Align slide rail laterally (equalize).
33    Pull up timing chain, position guide wheel (4) with left hand and knock-in lubricated bearing bolt by means of impact puller.
Screw-in screw connection with sealing ring.
m110 - 0055-3.jpg
 
 
Cham drive
1     Exhaust camshaft sprocket 2— 2b Sliding rail
3    Intake camshaft sprocket
4    Guide wheel
5    Lock bolt
6    Intermediate wheel
7    Timing chain
8    Crankshaft sprocket
9    Tensioning rail bearing pin
10    Tensioning rail
11     Hydraulic chain tensioner
 
 

 
 
01.2-415/10 F3
 
 

 
       

 

       
 

 
 
34 Install camshaft sprocket (6) of  intake camshaft with spacer (5). Lubricate spacer (3) with engine oil and slide it into bearing (4).
Intake
1     Expansion bolt
2    Washer
3    Spacer
4    Bearing
5    Spacer
6    Camshaft sprocket
7    Woodruff key
8    Camshaft
10    Camshaft housing
m110 - 0056-1.jpg
 
 

 
 
35 Install camshaft sprocket (6) of exhaust camshaft with timing chain. Lubricate spacer (3) with engine oil and slide it into bearing (4).
m110 - 0056-2.jpg
 
 
       
 
Exhaust camshaft
 
 
1
Expansion bolt
 
 
2
Washer
 
 
3
Spacer
 
 
4
Bearing
 
 
6
Camshaft sprocket
 
 
7
Woodruff key
 
 
9
Camshaft
 
 
10
Camshaft housing
 
       
 
 

 
 
36 During repair jobs, mount necked-down screw (3) with washer (2) only, but do not yet tighten.
m110 - 0056-3.jpg
 
 
1    Spacer 2nd version without lubricating groove (for pressure oil pump and vacuum pump 2nd version)
2    Washer
3    Expansion bolt
4    Dog (for pressure oil pump and vacuum pump 2nd version)
5    Dog (for vacuum pump 1st version)
6    Dog 1st version with lubricating groove
A = 4.7 mm for vacuum pump 1 st version
A = 8.3 mm for pressure oil pump and vacuum pump
2nd version
8    Spring washers (not valid)
9    Mounting bolt (not valid)
 
 

 
 
37 When 1st cylinder is at ignition TDC the adjust­ment marks on both camshaft sprockets and camshaft housing must align.
m110 - 0056-4.jpg
 
 

 
 
01.2-415/11 F3
 
 

 
       

 

       
 

 
 
Attention!
If the vibration damper of an engine has a "00" mark for BDC in addition to TDC, the TDC mark is next to pin (2) in the vibration damper.
m110 - 0057-1.jpg
 
 
1 TDC mark
 
 

 
 
38 Install sliding rail in camshaft housing so that the timing chain cannot jump.
m110 - 0057-2.jpg
 
 

 
 
39    Install rigid chain tensioner and tighten by hand.
40   Turn crankshaft with combination tool and ad­just to ignition TDC. Check adjustment marks (fig. of point 37).
Check timing, if cylinder head or camshaft housing surfaces have been faced (05—215).
41    Tighten necked-down screw for camshaft sprocket to 80 Nm (8 kpm), while applying counterhold to camshaft by means of holding wrench.
m110 - 0057-3.jpg
 
 

 
 
42 Install rocker arms and spring clamps (05—230).
m110 - 0057-4.jpg
'419
 
 

 
 
01.2-415/12 F3
 
 

 
       

 

       
 

 
 
43 Position chain tensioner for insallation and install (05-310).
m110 - 0058-1.jpg
 
 

 
 
44 Adjust valve clearance (05—210).
Further installation instructions in reverse sequence of removal.
m110 - 0058-2.jpg
 
 

 
 
01.2-415/13 F3