Cylinder Head Overview

Cylinder Head Overview

• Only remove the plastic protectors installed to protect the open valves immediately before fitting the cylinder head.

• When replacing the cylinder head or cylinder head gasket, the coolant must be completely replaced.

• Cylinder heads with cracks between the valve seats can continue to be used without reducing service life, as long as the cracks have a Max. width of 0.5 mm.

• 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 self-locking nuts, seals, gaskets and clamps.






1 Cylinder Head

• See the note above.

• Checking for distortion, refer to => [ Checking the Cylinder Head for Distortion ].

• Removing and installing, refer to => [ Cylinder Head ] Cylinder Head.

• All of the coolant must be replaced after installation.

• Checking the compression, refer to => [ Compression, Checking ] Testing and Inspection.

2 Washer

• For the cylinder head bolt.

3 Cylinder Head Bolt

• Observe the sequence for loosening and tightening, refer to => [ Cylinder Head ] Cylinder Head.

• Before installing, insert the washers - item 2 - into the cylinder head.

4 Stud Bolt

• 25 Nm

5 Lifting Eye

6 Gasket

• Always replace.

7 Vacuum Pump


Do not disassemble the vacuum pump under any circumstances because it can cause the vacuum part to malfunction. The result would be brake booster failure.

• Removing and installing, refer to => [ Vacuum Pump ] Service and Repair.

8 Bolt

• 10 Nm

9 Coolant Connection

• Coolant hose connection diagram. Refer to => [ Coolant Hose Connection Diagram ] [1][2]Cooling System.

10 Bolt

• 10 Nm

11 Seal

• Always replace.

12 Bolt

• 25 Nm

13 Lifting Eye

14 Cylinder Head Gasket

• Always replace.

• Observe the identification, refer to => [ Cylinder Head Gasket Identification ].

• All of the coolant must be replaced after removing and installing.

15 Camshaft Position Sensor (G40)

• For the camshaft position.

16 Bolt

• 10 Nm

Checking the Cylinder Head for Distortion





Special tools, testers and auxiliary items required

• Straight Edge 500 mm (VAS 6075)

• Feeler Gauge

Procedure

- Check the cylinder head for distortion using straight edge 500 mm (VAS 6075) and feeler gauge in several places.

• Max. permissible distortion: 0.10 mm

• Remanufacturing diesel cylinder heads is not permitted.

Cylinder Head Gasket Identification





• Part number = - arrow 1 -

• Control code = - arrow 2 - (ignore this!)

• Holes = - arrow 3 -

• Installed position: the mark faces up.

• Depending on piston projection, varying cylinder head gasket thicknesses can be installed. When replacing the gasket, install a new gasket with the same identification - arrow 3 -.

• Determine the piston position at Top Dead Center (TDC) when installing new pistons or a partial engine. Refer to => [ Piston Projection in TDC, Checking ] Testing and Inspection.