Removal and Installation

Cylinder Head

Special tools, testers and auxiliary items required

• Retainer (3036) for the left cylinder head

• Puller (T10320) for the left cylinder head

• Puller (T40064) for the left cylinder head

Removing

- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.

Left Cylinder Head

- Remove the high pressure pump toothed belt. Refer to => [ High Pressure Fuel Pump Toothed Belt ] High Pressure Fuel Pump Toothed Belt.

- Remove the high pressure pump toothed belt using (T40064).





- Using (3036), loosen the central bolt - 1 - for the toothed belt drive sprocket approximately two turns.





- Remove the toothed belt drive gear using (T10320).





- Remove the toothed belt drive sprocket with the toothed belt.

- Remove the bolts - arrows - and the rear toothed belt guard.





Right Cylinder Head through 10.05

- Remove the fuel supply line banjo bolt - 2 - and fuel return line banjo bolt - 1 - from the high pressure pump and lay it aside.





Right Cylinder Head from 11.05

- Remove the fuel supply line banjo bolt - 2 - and fuel return line banjo bolt - 1 - from the high pressure pump and lay it aside.





Continuation for Both sides

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

- Remove the left or right lower intake manifold. Refer to one of the following:

=> [ Lower Left Intake Manifold ] Lower Left Intake Manifold

=> [ Lower Right Intake Manifold ] Lower Right Intake Manifold

- Remove the affected camshaft timing chain from the camshafts. Refer to => [ Camshafts ] Camshafts.

- Remove the coolant ventilation line banjo bolt - item 8 -=> [ Banjo Bolt ] Cylinder Head Overview and the coolant ventilation line.

- Remove the intermediate exhaust pipes. Refer to:

=> [ Left Intermediate Pipe ] Left Intermediate Pipe

=> [ Right Intermediate Pipe ] Right Intermediate Pipe

- Remove the left or right cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

Right Cylinder Head





- Remove the right coolant pipe bolt - arrow - from the cylinder head.

Continuation for Both Sides





- Loosen the cylinder head bolts in the sequence shown.

- Remove the bolts and carefully remove cylinder head.

CAUTION!
Do not set the cylinder head down on the ends of the glow plug elements.

Installing

• Remanufacturing diesel cylinder heads is not permitted.

• Replace the cylinder head bolts.

• During assembly, replace self locking nuts and bolts.

• Always replace bolts that have been tightened to an angle specification as well as O-rings and gaskets.

• Carefully remove sealant residue from the cylinder head and cylinder block. Make sure that no long scrapes or scratches result.

• Carefully remove all grinding and sanding residue.

• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

• Only unpack the new cylinder head gasket immediately prior to installation.

• Handle the gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.

• Do not remove plastic sleeves protecting the valves until immediately before installing the cylinder head.

• When installing a replacement cylinder head with the camshafts installed, lubricate the contact surfaces between the roller rocker levers and the cam running surfaces.

• After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that the valves do not strike the pistons.

• Secure all hose connections using hose clamps appropriate for the model type. Refer to the parts catalog.

• Hose connections and charge air system hoses must be free of oil and grease before installing.

• Replace all of the coolant and engine oil when replacing the cylinder head or cylinder head gasket.

Installation is performed in reverse order of removal, noting the following:





- Rotate the crankshaft and the camshafts to the Top Dead Center (TDC) position before installing the cylinder head:

• The (3242) must be installed in the crankshaft - 1 - TDC opening.

• The camshafts in the cylinder head must be secured using (T40060).





- Note the cylinder head gasket identification:





1. Holes

2. Part number

• If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket.

• If the crankshaft drive is replaced, measure the piston projection in TDC to determine the new cylinder head. Refer to => [ Piston Projection in Top Dead Center, Checking ] Testing and Inspection.

• The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.

- Install the cylinder head gasket.





• Pay close attention to the alignment bushings in the cylinder block - arrows -.

• Pay attention to the installed position of the cylinder head gasket, the mark "oben" (top) or part number must face toward the cylinder head.

- Install the cylinder head.

- Install new cylinder head bolts and tighten them by hand.

- Tighten the cylinder head bolts in sequence - 1 through 8 - as follows:





- Tighten the bolts to 35 Nm.

- Tighten the bolts to 60 Nm.

- Tighten the bolts an additional 90° (1/4) turn.

- Tighten the bolts an additional 90° (1/4) turn.

• There is no requirement to tighten the cylinder head bolts after repairs.

- Install the left or right cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

- Install the camshaft timing chains. Refer to => [ Camshafts ] Camshafts.

- Install the intermediate exhaust pipe. Refer to:

=> [ Left Intermediate Pipe ] Left Intermediate Pipe

=> [ Right Intermediate Pipe ] Right Intermediate Pipe

- Install the left or right lower intake manifold. Refer to one of the following:

=> [ Lower Left Intake Manifold ] Lower Left Intake Manifold

=> [ Lower Right Intake Manifold ] Lower Right Intake Manifold

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

Left Cylinder Head

- Install the high pressure pump toothed belt. Refer to => [ High Pressure Fuel Pump Toothed Belt ] High Pressure Fuel Pump Toothed Belt.

Continuation for Both Sides

- Change the engine oil.

- Replace the coolant. Refer to => [ Draining and Filling ] Draining and Filling.

- Inspect the fuel system for leaks. Refer to => [ Fuel System, Performing Leak Test ] Fuel System, Performing Leak Test.

Tightening Specifications