11 12 100 Removing and installing cylinder head (N47D20 K/U/O/T 1)

Special tools required:

IMPORTANT: There must be no coolant, water and engine oil in any of the threaded holes in the engine block.
Fit new cylinder head bolts.
Do not wash off bolt coating.
Jointing torque and angle of rotation must be observed without fail (risk of damage!) .

Necessary preliminary tasks:

Disconnect negative lead from battery.
Remove CYLINDER HEAD COVER
Remove intake PLENUM
Release EXHAUST TURBOCHARGER from exhaust manifold
Drain and dispose of COOLANT
Remove EXHAUST-GAS RECIRCULATION COOLER
Disconnect coolant hoses
Remove CHAIN TENSIONER at top

Release coolant drain plug on engine block (if fitted).

Tightening torque: 11 11 2AZ .

Installation note:

Replace sealing ring.

Fig 1: Identifying Coolant Drain Plug On Engine Block

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Crank engine with special tool 11 6 480 in direction of rotation until piston of cylinder 1 is in TDC position.

Secure flywheel with special tool 11 5 320 in the TDC firing position of cylinder 1.

Fig 2: Securing Engine Using Special Tool (11 5 320)

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Release camshaft bolts (1).

Tightening torque: 11 31 1AZ .

Remove sprocket.

IMPORTANT: Protect timing chain to prevent it from falling.
Risk of damage to oil spray nozzle.

Fig 3: Identifying Camshaft Bolts

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Release bolts (1) from outside to inside.

Remove camshaft carrier with camshafts.

Fig 4: Identifying Camshaft Carrier Bolts

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Release screws (1).

Fig 5: Identifying Screws

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Release screws (1).

Fig 6: Identifying Screws

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Release cylinder head bolts in sequence 10 to 1.

Fig 7: Cylinder Head Bolts Tightening/Loosening Sequence (N47 D20 O1)

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IMPORTANT: All the glow elements protrude at the sealing surface and may be damaged when the cylinder head is put down.

IMPORTANT: Remove cylinder head and set down in such a way that glow elements are not damaged.

If necessary, remove glow elements with special tool 11 6 050 .

Fig 8: Locating Glow Elements

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Close oil duct at front using special tool (B) from tool set 2 364 711 .

IMPORTANT: Do not use any metal-cutting tools.

Fig 9: Identifying Front Oil Duct And Special Tool (2 364 711)

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Seal oil ducts at rear using special tool (B) from tool set 2 364 711 .

IMPORTANT: Do not use any metal-cutting tools.

Fig 10: Identifying Rear Oil Ducts And Special Tool (2 364 711)

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Seal oil duct at center using special tool (C) from tool set 2 364 711 .

IMPORTANT: Do not use any metal-cutting tools.

Fig 11: Identifying Center Oil Duct And Special Tool (2 364 711)

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Installation note:

Without repair work on the engine block which alters the piston protrusion, use a new cylinder head gasket with the same gasket thickness (number of holes).

Fig 12: Identifying Cylinder Head Gasket

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If work is carried out on the crank drive or piston, the gasket thickness must be redetermined.

Measuring the piston protrusion:

Fit dial gauge with measuring fixture special tool 00 2 530 on cleaned cylinder sealing surface and set under preload to zero.

Fig 13: Installing Dial Gauge On Engine Block Sealing Surface

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Clean piston at measuring points (1 and 2).

Fit dial gauge at measuring point (1) on cleaned piston and determine highest point by rotating crankshaft.

Measure and note down piston protrusion at measuring points (1 and 2) on all 4 pistons.

Installation note:

DETERMINE THICKNESS OF CYLINDER HEAD GASKET .

Fig 14: Measuring Piston Protrusion Using Dial Gauge

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Position special tool 00 2 530 with dial gauge (1) on cylinder head.

Set dial gauge (1) to zero.

Fig 15: Positioning Special Tool (00 2 530) With Dial Gauge On Cylinder Head

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Position special tool 00 2 530 with dial gauge (1) on valve.

Determine VALVE UNDER PROTRUSION .

Fig 16: Positioning Special Tool (00 2 530) With Dial Gauge On Valve

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Remove coarse residues on sealing surfaces with special tool 11 4 471 from cylinder head and crankcase.

IMPORTANT: Do not use any metal-cutting tools.

Fig 17: Removing Coarse Residues On Sealing Surfaces

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Remove fine residues on sealing surfaces with special tool 11 4 472 from cylinder head and crankcase.

IMPORTANT: Do not use any metal-cutting tools (e.g. abrasive cloth).
There must be no coolant, water or engine oil in the pocket holes.
Risk of cracking and corrosion!

Clean all blind holes.

Fig 18: Removing Fine Residues On Sealing Surfaces

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Check fitting sleeves (1) for damage and correct installation position.

Fig 19: Identifying Fitting Sleeves

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Fit new cylinder head gasket with previously determined gasket thickness (number of holes).

Fit cylinder head and secure with new bolts, tightening in the sequence 1 to 10.

Tightening torque: 11 12 1AZ .

Fig 20: Cylinder Head Bolts Tightening/Loosening Sequence (N47 D20 O1)

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Secure cylinder head bolts (1) with special tool 00 9 120 .

Fig 21: Securing Cylinder Head Bolts With Special Tool (00 9 120)

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Install and tighten down screws (1).

Fig 22: Identifying Screws

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Install and tighten down screws (1).

Fig 23: Identifying Screws

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Make sure that the hydraulic valve clearance compensating element (1) is installed in the correct position.

Fig 24: Installing Hydraulic Valve Clearance Compensating Element

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Make sure roller cam followers (1) are in correct installation position.

Fig 25: Locating Roller Cam Followers

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IMPORTANT: The camshaft sprockets (A and E) must be adjusted to the marking before the camshaft carrier is mounted on the cylinder head. Risk of damage! to engine valves.

Fig 26: Adjusting Camshaft Sprockets