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Cylinder Head, Disassemble and Reassemble
Disassemble
Remove cylinder head.
See corresponding operation.
Lay cylinder head on two pieces of wood and unscrew exhaust
manifold.
Unscrew thermostat housing and remove it along with
thermostat.
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Remove glow plug contact rail completely.
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Remove glow plugs.
Remove hose for injection pump fuel return line and unscrew
return line from injection nozzles.
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Remove injection nozzles.
Remove nozzle seal rings and corrugated washers.
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Remove swirl chambers.
To do this, prepare ad hoc tool as shown in accompanying
illustration.
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Insert ad hoc tool into swirl chamber via the glow plug
opening.
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Swirl Chamber, Check and Replace
Important:
When driving out the swirl chambers, take care not to damage
the sealing surface of the cylinder head cover.
Remove combustion deposits from inside chamber.
When doing this take care not to damage chamber mounting
points.
Important
Check inside surfaces of combustion chamber, swirl chamber
aperture and treated swirl chamber surfaces for cracks and other damage.
If necessary, the cylinder head should be replaced.
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Check swirl chambers for unacceptable level of wear and
other damage.
Replace swirl chamber if necessary.
Drive out heat protection sleeve with 8 mm/0.3 in.
brass drift from below.
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Loosen camshaft bearing cover screws and remove bearing
cover.
Remove camshaft.
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Pull out cup tappets with adjustment washers and lay aside
in proper sequence so that when reinstalling, tappets can be matched to
valves.
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Turn cylinder head and mark valves.
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Tension valve springs with Spring Tensioner
KM - 348 and Adapter KM - 653 and remove valve cones.
Remove valve spring with upper valve head.
Remove valves.
Remove lower valve spring plate with rod magnet.
Remove valve stem seal with commercially available special
pliers.
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Assembly
Insert swirl chamber positioning ball into groove in
cylinder head.
Place a metal washer approx. 25 mm/0.98 in. thick on
swirl chamber and press swirl chamber into place.
Important
Do not exceed a force of 2800 kp/6173 lbs. as otherwise the
cylinder head will be damaged.
Reduce swirl chamber projecting material with a flat
grinding machine.
After grinding, swirl chambers must be free of bumps and
must not have any recess.
Check that swirl chambers are securely seated by gently
tapping with a hammer.
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Swirl Chamber Projection, Check
Measure swirl chamber recess with straight edge and feeler
gauge in a straight line from the first swirl chamber to the fourth swirl
chamber.
Permissible swirl chamber projection:
0.0 to 0.03 mm.
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Insert heat sleeve via mounting opening for nozzle holder in
cylinder head and drive in with a 15 mm/0.59 in. Æ soft drift (brass or aluminium).
Flush side of heat sleeve must face up.
New hut sleeves must always be used.
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Insert corrugated washer.
Use new washers.
Important
Rounded side up.
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Install injector with new seal ring.
Important:
When installing, the marking (1) (bore hole or green dot) of
injector holder must coincide with marking (2) on cylinder head.
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Secure union nut with KM-728.
Counterhold injector holder with open wrench.
Torque: 50 Nm/37 lbf. ft.
Important:
Injector must not turn and markings
must coincide.
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Valve Indentation, Check
Insert valve in cylinder head.
Position dial gauge with support.
Place probe on sealing surface and set gauge at
"0".
Turn support until probe rests on valve head.
Read measured value.
Permissible valve indentation
0.5 to 1.0 mm/0.02 to 0.04 in.
Remove valve.
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Lubricate inside of valve stem seal with engine oil and
press onto valve guide until the inside lug catches in the valve guide
groove.
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Lubricate valve stem with engine oil and slide valve in.
Important
Do not damage valve stem seal.
Check that valve stem seal is properly seated.
Insert lower spring washer.
Push valve spring with narrower threaded end pointing
downwards onto spring washer.
Cover with upper spring washer.
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Tension valve spring with Spring Tensioner KM-348 and
Adapter KM - 653 and insert valve cones.
Check that valve cones are seated properly at upper spring
washer.
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Lubricate inside and outside of tappets, adjustment washers
on both sides and tappet bore in cylinder head with engine oil.
Install tappets in valves in same order in which they were
removed.
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Lubricate all bearing surfaces on camshaft and cylinder head
with engine oil.
Install camshaft with positioning pin pointing upwards.
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Apply Sealing Compound
15 04 200 (8 983 368) to 1st camshaft bearing as
shown (see illus. C 7051).
Be careful that no sealing compound gets onto the camshaft.
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Install bearing cover and tighten nuts in order indicated to
prescribed torque.
Torque: 25 Nm/18 lbf. ft.
Important
Under no circumstances must cylinder head with camshaft
installed be laid on mounting surface: valves will be damaged.
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Lubricate sealing lip of camshaft with engine oil and drive
in seal ring with Installer KM-656.
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