Cylinder head removal & torque: Mercedes-Benz eng 124, 201 2.5 D (602.911, 602.912, 602.961, 602.962)

🧭 Before you start

Fits: platform codes 190D, 2.5, |, TURBO, 250, D, TURBODIESEL, -TD

• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• Mark the timing chain and camshaft gearwheels to each other with paint

🔧 Engine codes this applies to

📋 Procedure

Preparation and removal

1. Mark the timing chain and camshaft gearwheels to each other with paint
2. All vehicles:
3. Remove the camshaft gearwheel
4. Note: Lock the camshaft
5. Remove the camshaft bearing caps

6. Remove the clamp(s)
7. Remove the hydraulic tappets
8. Remove the injector nozzles
9. Fully clamp the hoses
10. Remove the clips
11. Remove the clamp(s)
12. All vehicles:
13. Remove the clips
14. Remove the ancillary drive belt
15. Remove the air filter with the inlet hose
16. Unbolt the dipstick tube bracket
17. All vehicles:
18. Disconnect the front exhaust pipe from the turbocharger
19. Disconnect the heater hose from the cylinder head
20. Vehicles with self-levelling suspension:
21. Remove the chain guide(s)
22. Remove the cylinder head bolts
23. Remove the cylinder head gasket

Installation and checks

24. Special tool
25. Fit the cylinder head gasket
26. Special tool
27. Tighten the cylinder head bolts
28. Cylinder head torque settings - Refer to 'Adjustment data/Torque settings'
29. Refit the guide pins
30. Stage 1:
31. Stage 1:
32. Stage 2:
33. Refit the fuel filter
34. Fit the ancillary drive belt
35. Refit the clips
36. Refit the bonnet lock release cable
37. Refit the clips
38. Reconnect the radiator hoses
39. Refit the clips
40. Vehicles with automatic transmission
41. Reconnect the oil cooler hoses
42. Refit the injector nozzles
43. Refit the camshaft bearing caps
44. In the order shown
45. Stage 2:
46. Check the camshaft timing marks
47. Stage 1:
48. Stage 2:
49. Check the crankshaft timing marks
50. Fit the chain tensioner
51. Check the timing marks again
52. Refit the engine lower covers
53. Reconnect the battery earth cable

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