Cylinder Head, Removing And Installing: Installing:

-- Carefully remove metal particles, emery remains and cloths.

If the piston for No. 1 cylinder is not at TDC:

-- Turn the crankshaft in the direction of engine rotation to TDC cylinder 1 -arrow- while a second technician guides the camshaft timing chain by hand.

Fig 1: Identifying Cylinder 1 At Top Dead Center (TDC) Mark

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-- Make sure that alignment bushings are inserted in bore 12 and 20 in cylinder block.

Fig 2: Cylinder Head Bolts Tightening Sequence

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-- Apply a 2 mm thick bead of Sealant: D 176 501 A1  as shown -arrows- to the gap between the cylinder block and sealing flange.

Fig 3: Identifying Sealant Location For Cylinder Block/Sealing Flange

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-- Immediately place new cylinder head gasket on. The text (part number) must be visible.

-- Also add some Sealant: D 176 501 A1  to both 3 mm holes that are located on the sealant bead.

-- Position the camshafts in cylinder head to Top Dead Center (TDC) cylinder 1.

Cams -A- of cylinder 1 must face each other.

Fig 4: Camshaft Lobes For Cylinder Facing Each Other

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-- It must be possible to insert the : T10068A  in both shaft Grooves.

Fig 5: Identifying Camshaft Bar T10068 A Engage In Shaft Grooves

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-- Now, cylinder head can be installed.

-- Apply Locking Fluid : D 197 300 A2  to each cylinder head bolt in the cylinder head contact surface -arrow- and insert the bolts.

Fig 6: Applying Liquid Locking Fluid To Cylinder Head Bolt

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-- Tighten cylinder head bolts in specified sequence, starting from inside and working toward outside, as follows:

Fig 7: Cylinder Head Bolts Tightening Sequence

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1. Pre-Tighten All Bolts to 15 Nm.
2. Then Tighten All Bolts to 30 Nm.
3. Turn Another 90° Using a Rigid Wrench.
4. Turn Another 90° Using a Rigid Wrench.

-- Lubricate the sealing rings of the camshafts and install the control housing. The camshaft timing chain must be placed over the camshaft adjuster valves.

Fig 8: Identifying Control Housing And Bolts

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-- Secure the high pressure pump drive pinion in position with the :T10363  . The marking -A- on the on high pressure drive cams must be at the top.

Fig 9: Securing Position Of Drive Pinion For High Pressure Pump Using Adjustment Tool T10363

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-- Install the camshaft timing chain on the high pressure pump chain sprocket so that it is >>taut<< and then screw on the slide rail -arrow-.

Fig 10: Identifying Guide Rail Bolt

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Assemble in reverse order of disassembly.

-- Camshaft adjuster with camshaft timing chain, installing. Refer to CAMSHAFT ADJUSTER, REMOVING AND INSTALLING .

-- Install the cylinder head cover and intake manifold. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .