Overhaul
Cylinder head, assembly overview
1 - Toothed belt cover - upper part
2 - Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
3 - 10 Nm
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 puller T10052
8 - Rear toothed belt cover
9 - Grommet
^ Replace if damaged
10 - Camshaft Position (CMP) sensor -G40-
^ For camshaft position
11 - Cylinder head bolt
^ Replace
^ Observe sequence for loosening and tightening
12 - Cylinder head cover
^ Before installing, clean contact surface of cylinder head with clean shop rag
13 - To turbocharger
14 - Pressure regulator valve
^ For crankcase ventilation
15 - Cap
^ Replace seal if damaged
16 - Sealing sleeve
^ Replace if damaged
17 - 10 Nm
^ First, fasten all bolts hand-tight
18 - Seal for cylinder head cover
^ Only replace together with cylinder head cover
^ Before installing, seal contact surfaces with sealant AMV 174 004 01.
19 - 20 Nm
20 - Lifting eye
21 - Pump-Injector unit
22 - Central harness connector
^ For Pump-Injector unit
23 - From brake booster
24 - Tandem pump
^ For fuel and vacuum supply
25 - Supply hose
^ White or with white markings
^ Ensure seated tightly
^ Secure with spring-type clips
26 - Return hose
^ Blue or with blue marking
^ Ensure seated tightly
^ Secure with spring-type clips
27 - Seal
^ Replace
28 - Bolt
29 - Bracket
^ For fuel filter
30 - Cylinder head
^ After replacing replace entire amount of coolant
31 - Cylinder head gasket
^ Replace
^ Observe identification
^ After replacing replace entire amount of coolant
32 - Ceramic glow plug
^ 15 Nm
^ Absolutely observe all assembly guidelines and notes
33 - Tensioning roller
34 - 20 Nm plus an additional 1/8 turn (45°)
Checking cylinder head for distortion
Special tools, testers and auxiliary items required
^ Straight edge
^ Feeler gauge
Max. permissible distortion: 0.1 mm
Note: Remanufacturing of diesel cylinder heads is not permitted.
Cylinder head gasket identification
^ Replacement part No. = arrow 1
^ Control code = arrow 2 (ignore this!)
^ Holes = arrow 3
Note:
^ Depending on piston projection, varying cylinder head gasket thicknesses can be installed. When replacing a head gasket, install a gasket with the same identification.
^ When installing new pistons or working with a partial motor, check the piston position at TDC.