Cylinder Head Assembly Overview
Cylinder Head Assembly Overview
• 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.
• Cylinder heads with cracks between the valve seats can continue to be used without reducing service life, as long as the tears have a width of max. 0.5 mm.
• Do not mill the valve seats in the cylinder head; only grinding of the valves is permissible.
• After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons).
• After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.
• Always replace gaskets and seals.
1 Toothed belt cover, upper
2 Toothed belt
• Mark direction of rotation before removing
• Check for wear
• Do not kink
• Removing and installing, tensioning => [ Toothed Belt ] Toothed Belt.
3 10 Nm
• Replace
4 25 Nm
5 100 Nm
6 Camshaft sprocket
7 Hub
• With sensor wheel
• Use counter-holder (T10051) to loosen and tighten
• To remove, use pulling fixture (T10052)
• Removing and installing => [ Camshaft ] Service and Repair.
8 Toothed belt cover, rear
9 Grommet
• Replace if damaged
10 Camshaft Position (CMP) sensor (G40)
• For camshaft position
• To remove, remove grommet => [ (Item 9) Grommet ] from rear of toothed belt cover
11 Stud bolt
• 15 Nm
12 Cylinder head bolt
• Follow sequence for loosening and tightening => [ Cylinder Head ] Cylinder Head.
• Place washers into cylinder head before installing => [ (Item 4) Washer ] Valvetrain Assembly Overview
13 Fuel return line
14 Fuel supply line
15 Coolant line
16 Cylinder head cover
• Always clean sealing surfaces of cylinder head with a clean cloth before setting in place
17 Pressure regulator valve
• For crankcase ventilation
18 To turbocharger
19 Cap
• Replace gaskets if damaged
20 Sealing sleeve
• Replace if damaged
21 10 Nm
• Observe tightening sequence => [ Cylinder Head Cover ] Service and Repair.
22 Cylinder head cover gasket
• Only replace together with cylinder head cover
• Before installing, seal contact surfaces with sealant, black (AMV 174 004 01) for transmission housing => [ Cylinder Head Cover ] Service and Repair.
23 20 Nm
24 Lifting eye
25 Pump injector unit
• Removing and installing => [ Pump Injector Unit ] Pump Injector Unit.
26 10 Nm
27 Central harness connector
• For pump-injector unit
28 From brake booster
29 Tandem pump
CAUTION!
Pay attention to the notes when reinstalling a running tandem pump => [ Installing ] Tandem Pump
• For fuel and vacuum supply
• Checking => [ Tandem Pump, Checking ] Tandem Pump, Checking.
• Removing and installing => [ Tandem Pump ] Tandem Pump.
• Must not be disassembled
30 Supply hose
• From fuel filter => [ Fuel Filter Assembly Overview ] Service and Repair.
• White or with white markings
• Ensure seated tightly
• Secure with spring-type clips
31 Return hose
• To fuel filter => [ Fuel Filter Assembly Overview ] Service and Repair.
• Blue or with blue marking
• Ensure seated tightly
• Secure with spring-type clips
32 Gasket
• Replace
33 Bracket
34 Bolt
35 Cylinder head
• Removing and installing => [ Cylinder Head ] Cylinder Head.
• After replacing replace entire amount of coolant
36 Cylinder head gasket
• Replace
• Observe identification => [ Identification of Cylinder Head Gasket ]
• After replacing replace entire amount of coolant
37 Glow plug/ceramic glow plug
• 15 Nm
• Absolutely observe all assembly guidelines and notes => [ Glow Plug Identification ] Application and ID.
• Checking => [ Glow Plug Identification ] Application and ID.
38 Tensioning roller
39 20 Nm + 45° (1/8 turn) additional turn
Checking Cylinder head for distortion
Special tools, testers and auxiliary items required
• Straight edge
• Feeler gauge
Max. permissible distortion: 0.05 mm
• Remanufacturing diesel cylinder heads is not permitted.
Identification of Cylinder Head Gasket
• 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.
• When installing new pistons or working with a partial motor, check the piston position at TDC => [ Piston Position at TDC, Checking ] Piston Position at TDC, Checking.