11 12 100 Removing and installing cylinder head (N47 D20 O1)

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 ground cable from battery. See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD .
Remove CYLINDER HEAD COVER .
Check TIMING .
REMOVE intake plenum.
Undo EXHAUST TURBOCHARGER from exhaust manifold.
Drain and dispose of COOLANT .
REMOVE EXHAUST-GAS RECIRCULATION COOLER
DISCONNECT COOLANT HOSES .

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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Turn engine with special tool 11 6 480 in direction of rotation until the piston at the first cylinder is in the "top dead center" top position.

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

Remove CHAIN TENSIONER .

Fig 2: Securing Flywheel 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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Installation note:

Before cleaning the sealing surfaces using the special tools 11 4 471 and 11 4 472 the risers for the oil ducts must be sealed.

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

IMPORTANT: Do not use any metal-cutting tools.

Fig 8: Identifying Front Seal 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 9: Identifying Rear Seal 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 10: Identifying Center Seal Oil Duct And Special Tool (2 364 711)

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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.

Graphic N52.

Fig 11: Identifying Special Tool (11 4 471)

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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!

Fig 12: Identifying Special Tool (11 4 472)

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Clean all blind holes.

Graphic N52.

IMPORTANT: All glow elements protrude at the sealing surface and may be damaged when put down.
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 13: Locating Glow Elements

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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 14: Identifying Thickness Marking

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If repair 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 15: 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 16: Measuring Piston Protrusion Points On Pistons

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

Set dial gauge (1) to zero.

Fig 17: 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 18: Positioning Special Tool (00 2 530) With Dial Gauge On Valve

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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

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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: Identifying Camshaft Sprocket Markings