Cylinder head OM611 in W638 (Vito) — MERCEDES-BENZ

🧭 Before you start

Fits: platform codes 108, CDI, |, 110, 112, V, 200, 220

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking tool
• Renewed: bolts note

🔧 Engine codes this applies to

📐 63 workshop diagrams for 611.980

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Before disconnecting the battery cable, check the audio system security code
2. Installation is in the reverse order of removal
3. Cylinder head torque settings - Refer to 'Adjustment data/Torque settings'
4. Support the engine
5. Remove the engine support

6. Remove the air inlet box
7. Remove the engine cover
8. Release the fuel pressure
9. Remove the injector lines
10. Remove the injectors
11. Note: Refit the injectors in their original cylinder
12. Note: Use new bolts
13. Note: If the injectors cannot be removed easily, use a special tool for removal
14. Remove the valve cover
15. Turn the crankshaft to TDC for cylinder 1
16. Check the camshaft timing marks
17. Check the crankshaft timing marks
18. Lock the camshaft
19. Use a special tool:
20. Remove the vacuum pump
21. Remove the low-pressure pump
22. Remove the chain tensioner
23. Disconnect the timing chain cover from the chain guide
24. Remove the timing chain cover
25. Remove the chain guide(s)
26. Remove the locking tool
27. Remove the exhaust camshaft gearwheel
28. During the removal of the camshaft gearwheel, the timing chain should remain in position
29. Remove the camshaft bearing caps
30. Remove the camshafts
31. Remove the tappets with a magnetic tool
32. Remove the camshaft housing
33. Remove the fuel shut-off valve
34. Remove the high-pressure pump
35. Remove the high-pressure pump gearwheel
36. Remove the inlet manifold
37. Disconnect the front exhaust pipe from the turbo
38. Remove the exhaust manifold
39. Disconnect the remaining wiring and hoses from the cylinder head
40. Remove the cylinder head bolts
41. Remove the cylinder head

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