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Cylinder Head, Remove and Install
(Illustrations show 15 D)
Remove
Remove intake manifold.
See operation "Gasket between Intake Manifold and Cylinder
Head, Replace".
Remove toothed belt.
See operation "Toothed Belt, Replace".
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Loosen camshaft timing gear retaining bolts, unscrew TDC
fixing bolts and remove gear.
Remove cylinder head cover.
Unbolt front plate from cylinder head.
Remove camshaft housing cover.
Unbolt front exhaust pipe from exhaust manifold.
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Remove injection lines and nozzle return lines.
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Detach hose connections from thermostat housing.
Pull water pipe out of water outlet connection (only
15 D).
Collect escaping coolant.
Detach thermosensor and thermoswitch.
Unscrew oil dipstick tube from cylinder head and pull out of
engine block.
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Loosen cylinder head bolts with
KM - 134 - A in sequence shown in illustration and
remove.
Note:
Remove cylinder head only when engine is cold.
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Lift off cylinder head. Press front plate slightly forward
when doing so.
Remove cylinder head gasket. Clean mating surfaces.
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Install
Measure piston head projection at three points per piston
and determine the average of all 12 measurements.
Remove combustion residues from piston head and cylinder
head before measuring.
Place magnet holder with gauge on piston head and set gauge
to "0".
Turn magnet holder until probe tip of dial gauge rests on
sealing surface of cylinder block.
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Select cylinder head gasket:
Average piston projection - Cylinder head gasket
0.58 to 0.64 mm -
1.35 mm A = one notch
0.65 to 0.70 mm -
1.40 mm B = two notches
0.71 to 0.78 mm -
1.45 mm C = three notches
If the measurement of the piston projection shows that even
one of the total of 12 measured values exceeds the upper limit of the gasket
selection range in question by 0.05 mm/0.002 in. or more, then select
the next gasket class.
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Install cylinder head gasket and cylinder head.
Tighten cylinder head bolts spirally from inner to outer in
3 stages with KM - 134 - A and
KM - 470 - B.
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For torque see "Technical Data".
Note:
Always use new cylinder head bolts.
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Install cylinder head cover with new gasket and tighten.
Torque: 8 Nm/6 lbf. ft.
Insert oil dipstick guide tube with new seal ring in engine
block.
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Secure oil dipstick guide tube to cylinder head.
Attach thermosensor and thermoswitch.
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Install hose connections on thermostat housing.
Insert coolant pipe in coolant escape connection.
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Install injection lines and nozzle return lines with new
seal rings.
Torque:
Injection line to injection nozzle and injection
pump: 25 Nm/18 lbf. ft.
Fuel return line to injection
nozzle: 30 Nm/22 lbf. ft.
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Bolt front plate onto cylinder head.
Prescribed torque: 10 Nm/7 lbf. ft.
Position camshaft gear onto camshaft in such a way that the
alignment borehole of the gear is pushed onto the camshaft alignment pin.
Counterhold camshaft timing gear with TDC fixing bolt and
tighten retaining bolts.
Prescribed torque: 10 Nm/7 lbf. ft.
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Bolt front exhaust pipe onto exhaust manifold.
Install toothed belt.
See operation "Toothed Belt, Replace".
Install intake manifold.
See operation "Gasket between Intake Manifold and Cylinder
Head, Replace".
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