Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Retainer (3036)

• Puller (T10320)

• Puller (T40064)

• Adjustment Pin (T40060)

Removing

- Drain the coolant. Refer to => [ Coolant, Draining ] Coolant, Draining.

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 sprocket using the puller (T40064).






- Using the retainer (3036) , loosen the center bolt - 1 - for the toothed belt pulley approximately two turns.






- Remove the toothed belt pulley using the puller (T10320).






- Remove the toothed belt pulley with the toothed belt.

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






- Remove the fuel supply line bolt - 2 - and the fuel return line bolt - 1 - from the high pressure pump and lay the lines 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 Intake Manifold, Left Side ] Lower Intake Manifold, Left Side.

=> [ Lower Intake Manifold, Right Side ] Lower Intake Manifold, Right Side.

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

- Remove the banjo bolt and the coolant ventilation line.

- Remove the intermediate pipes. Refer to the following:

=> [ 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 ] Cylinder Head Cover.

Right Cylinder Head






- Remove the right coolant pipe bolts - arrows - from the cylinder head.

Continuation for Both Sides






- Loosen the cylinder head bolts in sequence - 1 through 8 -.

- Remove the bolts and carefully remove the cylinder head.

Do not lay the removed cylinder head on the sealing surface with the glow plugs installed, the glow plugs protrude slightly past the cylinder head.

Installing

• Remanufacturing diesel cylinder heads is not permitted.

• Replace the cylinder head bolts.

• During assembly, replace any self-locking nuts and bolts.

• Always replace bolts that are tightened to an additional torque angle as well as O-rings and gaskets.

• Carefully remove any 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 cylinder head bolt holes in the cylinder block.

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

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

• Do not remove the 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 arms and the cam running surfaces.

• After working on the valvetrain and adjusters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that 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.

• Use the sealant provided. Refer to the Parts Catalog.

Install in the reverse order of removal. Note the following:






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

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

• The camshafts for both cylinder heads must be secured using the adjustment pin (T40060).






- Note the cylinder head gasket identification:






1. Holes

2. Part number:


• If the cylinder head gasket or the cylinder head were replaced, install 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 TDC, Checking ] Testing and Inspection.

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

- Clean any oil or grease off the sealing surfaces.

• Note the expiration date of the sealant.






- Cut the sealant tube nozzle at the front mark (nozzle diameter approximately 5 mm).

Left Cylinder Head

- Apply beads of sealant - 1 and 2 - on the clean sealing surfaces of the cylinder block and the lower timing chain cover as illustrated.






- Apply the sealant in the amounts specified.






• a = 7 mm

• b = 7 mm

• c = 7 mm

- Set the cylinder head gasket in place.

- Apply beads of sealant - 1 and 2 - to the clean sealing surfaces as illustrated.






Right Cylinder Head

- Apply beads of sealant - 1 and 2 - to the clean sealing surfaces of the cylinder block and the lower timing chain cover as illustrated.






- Apply the sealant in the amounts specified.






• a = 7 mm

• b = 7 mm

• c = 7 mm

- Set the cylinder head gasket in place.

- Apply beads of sealant - 1 and 2 - to the clean sealing surfaces as illustrated.






Continuation for Both Sides






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

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

- Install the cylinder head.

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

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






- Tighten the bolts to 35 Nm using a torque wrench.

- Tighten the bolts to 60 Nm using a torque wrench.

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

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

• There is no requirement to retighten the cylinder head bolts after the repair.

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

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

- Install the intermediate pipes. Refer to the following:

=> [ 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 Intake Manifold, Left Side ] Lower Intake Manifold, Left Side.

=> [ Lower Intake Manifold, Right Side ] Lower Intake Manifold, Right Side.

- 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 => [ Coolant, Filling ] Coolant, Filling.

- Inspect the fuel system for leaks. Refer to => [ Fuel System, Checking for Leaks ] Fuel System, Checking for Leaks.

Tightening Specifications