Cylinder Head Assembly Overview
Cylinder Head Assembly Overview
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
• When using an exchanged cylinder head with camshaft installed, the contact surfaces between the lifters and cam lobes must be lubricated before installing the cylinder head cover.
• The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head.
• When cylinder head is replaced, all coolant must also be replaced.
1 Cylinder head cover
• Removing and installing => [ Cylinder Head Cover ] Service and Repair.
2 Pressure regulator valve
• For crankcase ventilation
3 Ventilation hose
• Via the rear charge air pipe to the turbocharger
4 Cap
• Replace gaskets if damaged
5 Sealing sleeve
• Replace if damaged
6 10 Nm
• Note the tightening sequence => [ Cylinder Head Cover ] Service and Repair.
7 Gasket for cylinder head cover
• Replace if damaged or leaking
• Before mounting, seal the contact surfaces with (AMV 174 004 01 )=> [ Cylinder Head Cover ] Service and Repair.
• Install the nubs into the holes in the cylinder head
8 20 Nm
9 Lifting eye
10 Central harness connector
• For pump-injector unit
11 10 Nm
12 From brake booster
13 Tandem pump
• For fuel and vacuum supply
• Checking => [ Tandem Pump, Checking ] Tandem Pump, Checking.
• Removing and installing => [ Tandem Pump ] Tandem Pump.
14 25 Nm
15 Supply hose
• From fuel filter => [ (Item 8) Supply line ] Fuel Filter Assembly Overview
• White or with white markings
• Ensure seated tightly
• Secure with spring-type clips
16 Return hose
• To fuel filter => [ (Item 7) Return line ] Fuel Filter Assembly Overview
• Blue or with blue marking
• Ensure seated tightly
• Secure with spring-type clips
17 Gasket
• Replace
• 1- or 2-piece
18 20 Nm
19 Ball head screw, 8 Nm
20 Bracket
• For engine cover
21 Lifting eye
• With engine cover bracket
22 Cylinder head gasket
• Replace
• Observe identification => [ Cylinder Head Gasket Identification ]
• After replacing replace entire amount of coolant
23 20 Nm
24 Cylinder head
• Check for distortion => [ Checking Cylinder Head for Distortion ]
• Removing and installing => [ Cylinder Head ] Cylinder Head.
• After replacing replace entire amount of coolant
25 10 Nm
• Replace
26 Camshaft Position (CMP) sensor (G40)
• For camshaft position
• To remove, remove grommet from rear of toothed belt cover
27 Glow plug
• 15 Nm
• Checking, removing and installing => [ Glow Plugs ] Glow Plugs.
28 Pump-injector unit
• Removing and installing => [ Pump Injector Unit ] Pump Injector Unit.
29 Cylinder head bolt
• Observe sequence for loosening and tightening => [ Cylinder Head ] Cylinder Head.
• Before installing, insert the washers into the cylinder head => [ (Item 4) Washer ] Service and Repair
Checking Cylinder Head for Distortion
Special tools, testers and auxiliary items required
• Straight edge
• Feeler gauge
Max. permissible distortion: 0.05 mm (minimum distance of the linear surface: 100 mm)
• Remanufacturing diesel cylinder heads is not permitted.
Cylinder Head Gasket Identification
• Replacement part No. = - arrow 1 -
• Control code = - arrow 2 - (ignore this!)
• Holes = - arrow 3 -
• Depending on piston projection, varying cylinder head gasket thicknesses can be installed. When replacing a head gasket, install a head gasket with the same identification.