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Cylinder Head, Remove and Install (16 DA, 17D)
Disconnect
negative cable from battery.
Detach
lower coolant hose from radiator and drain coolant.
Remove
air cleaner housing with filter element.
Disconnect
all hoses and lines leading to cylinder head or camshaft housing.
Detach
injection lines from injectors and injection pump.
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Loosen
tensioning bar of alternator and remove V-belt.
Remove
upper and lower toothed belt covering.
Remove
front exhaust pipe.
Unbolt
cover from clutch housing.
Turn
crankshaft in rotational direction of engine until "TDC" mark on
flywheel coincides with mark on injection pump.
Unbolt
cover of camshaft housing.
Unbolt
vacuum pump.
Loosen
fastening bolts of water pump and swing water pump using Wrench KM-509-A.
Release
tension of toothed belt and remove.
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Loosen
fastening bolt of camshaft sprocket.
To
do this, counterhold camshaft with flat spanner.
Remove
cylinder head bolts in a spiral from outside to inside.
Remove
camshaft housing.
Lift
cylinder head with intake and exhaust manifolds from engine block.
Clean
sealing surfaces of engine block, cylinder head and camshaft housing.
To
clean cylinder head sealing surface, remove rocker arms, thrust pieces and
valve lash adjusters. Re-install after cleaning is completed.
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Position
new cylinder head gasket.
Attention:
Three
different thicknesses.
If
valves touch pistons, piston projection must be measured.
Use
a different thickness of gasket if necessary.
See
corresponding operation in this group and Technical Data.
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Position
cylinder head.
Coat
sealing surfaces of cylinder head and camshaft housing with sealing compound
15 03 166 (90 094 714).
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Position
camshaft housing.
Insert
cylinder head bolts and tighten uniformly in a spiral from inside to outside.
See
Technical Date for prescribed torque.
Important!
Cylinder head bolts must be tightened in four stages.
See
Technical Date for prescribed torque and angles.
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Mount
and tension toothed belt.
See
corresponding operation in this group.
Tighten
water pump fastening bolts.
Check
that all adjustment marks coincide and correct if necessary.
Loosely
tighten camshaft sprocket.
Check
and adjust valve timing.
See
corresponding operation in this group.
Tighten
camshaft sprocket fully - Note: prescribed torque.
Install
vacuum pump and mount camshaft housing cover.
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Install
upper and lower toothed belt covering.
Mount
and tension V-belt and tighten tensioning bar.
Connect
all hoses and cables leading to cylinder head and camshaft housing.
Screw
fuel lines to injection pump and to injectors.
Mount
air cleaner housing with air cleaner element.
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Install
front exhaust pipe.
Bolt
cover to clutch housing.
Fill
coolant into expansion tank as far as "KALT" mark.
Bleed
coolant system via screw on thermostat housing.
Connect
ground strap to battery.
Run
engine until warm (operation temperature).
Re-tighten
cylinder head bolts.
Attention:
After
600 miles/1000 km, re-tighten cylinder head bolts again.
See
Technical Data.
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