11 12 100 Removing and installing cylinder head (N57 Diesel)

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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.
Joining torque and angle of rotation must be observed without fail (risk of damage.) .
Reworking of cylinder head is not permitted.

Necessary preliminary tasks:

REMOVING CYLINDER HEAD COVER .
Remove INJECTOR NOZZLES .
Remove INTAKE PLENUM .
Undo negative lead from battery.
Undo TURBOCHARGER from exhaust manifold.
Drain and dispose of COOLANT .
Remove EXHAUST-GAS RECIRCULATION COOLER .
Disconnect COOLANT HOSES .

Open coolant drain plug on engine block.

Tightening torque 11 11 2AZ .

Installation note:

Replace gasket.

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.

Use special tool 11 5 320 to secure flywheel in TDC firing position of cylinder 1.

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

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Remove CHAIN TENSIONER at top.

Release camshaft bolts (1).

Tightening torque 11 31 1AZ .

Remove camshaft sprocket.

Fig 3: Identifying Camshaft Bolts

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Release screws (1) from outside inwards in 1/2 turns.

Remove camshaft carrier.

Fig 4: Identifying Screws Of Camshaft Carrier

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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 screws (1 to 14) from outside inwards in 1/2 turns.

Remove cylinder head.

Fig 7: Cylinder Head Bolts Tightening/Loosening Sequence (N57)

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

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

Fig 9: Identifying Thickness Marking

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Clean sealing surfaces with special tool 11 4 470 .

Check evenness of cylinder head (1) with a straightedge (2).

Max. deviation from flatness (longitudinal) 0.10 mm .

Max. deviation from flatness (transverse) 0.05 mm .

Fig 10: Checking Evenness Of Cylinder Head With Straightedge

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

Determine valve under-protrusion.

Fig 11: Positioning Special Tool (00 2 530) With Dial Gauge On Valve

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

Set dial gauge (1) to zero.

Fig 12: Positioning Special Tool (00 2 530) With Dial Gauge On Cylinder Head

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Clean sealing surfaces with special tool 11 4 470 .

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: Measuring Piston Protrusion

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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 At Points On Pistons

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Installation note:

Coat transition from crankcase to gear case cover with Drei Bond 1209 sealing compound.

Fig 15: Identifying Crankcase-To-Gearcase Cover Sealing Surfaces

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

Clean sealing surfaces with special tool 11 4 470 .

Reinstall cylinder head gasket.

Fig 16: Identifying Fitting Sleeves

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

Fig 17: Identifying Cylinder Head Bolts And Special Tool (00 9 120)

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Tighten cylinder head bolts in sequence (1 to 14).

Tightening torque: 11 12 1AZ .

Install and tighten down screws (1).

Tightening torque: 11 00 4AZ .

Fig 18: Cylinder Head Bolts Tightening/Loosening Sequence (N57)

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Install and tighten down screws (1).

Tightening torque: 11 00 4AZ .

Fig 19: Identifying Screws

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Fig 20: Identifying Screws

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

Fig 21: Installing Hydraulic Valve Clearance Compensating Element

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

Fig 22: Identifying Roller Cam Follower

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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 23: Identifying Camshaft Sprockets