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Valve gear

Valve gear

To remove


Important

The cylindrical surfaces surrounding the valve springs are sealing surfaces for the valve tappets. These surfaces must not be scored. Therefore, protect the valve tappet cylinders with protective sleeves 83 93 746.



1. Remove the cylinder head, see , and place it in such a way that the fuel injectors, glow plugs or valves are not damaged.

2. Remove the exhaust manifold with turbocharger and the generator bracket.

3. Remove the glow plugs.

4. Remove the upper part of the intake manifold, the lifting eyes and the lower part of the intake manifold.

5. Remove the thermostat housing and the coolant temperature sensor.

6. Remove the camshaft bearing caps in stages, 0.5-1 turn in a spiral formation starting with cap 1.


Important

Camshaft bearing cap markings.


7. Lift off the camshaft bearing caps and remove the camshaft.

Important

The camshaft must be detached evenly from the bearing seats.


8. Remove the fuel bridge retaining bolts and pull the fuel bridges out of the cylinder head.

9. Remove the seals on the injector connections in the cylinder head.


10. Screw adapter 83 95 378 onto the fuel injectors, fit puller 87 91 360 onto the adapter and pull out the fuel injectors.

11. Remove the seals from the fuel injectors.

12. Remove the valve bridges.

Important

Note how and where the valve bridges are fitted. The markings on the valve bridges must be closest to the fuel bridges.


13. Lift up the valve tappets with magnetic tool 83 91 401 and fit protective sleeves 83 95 022.


14. Mark the valves so that they can be refitted in the correct positions.

15. Fit valve compressor 83 95 246 onto the cylinder head. Press down the lever and remove the valve cones.

16. Lift out the spring disc and valve spring. Remove the valve guide seal with pliers 83 94 157 and lift up the lower spring disc.


17. Remove the valves and place them in valve stand 83 93 787.


To fit


Important

Defective valve stem seals must be replaced and sealing surfaces and bearings oiled before fitting the valves. Make sure the cylinder head is supported on blocks so that the valves are not bent when the camshaft is drawn down.



1. Clean all the parts and check sealing surfaces, sliding surfaces and bearing surfaces for wear.

2. Lubricate the valves with engine oil and fit them in the correct positions according to the markings made earlier.

3. Fit the lower spring disc, lubricate the valve stem seals with engine oil and fit them with tool 83 95 071. Fit the spring and spring disc and place the cones in the groove in the spring disc.

4. Press down the lever on the valve compressor and fit the valve cones.


5. Fit new seals on the fuel injectors and fit the injectors.


6. Fit new seals on the injector connections in the cylinder head. Remove any remains from old seals.

7. Remove the protective sleeves, lubricate the valve tappets with engine oil and position them in the cylinder head.


8. Fit the valve bridges.

Important

Note how the valve bridges are fitted. The markings on the valve bridges must be closest to the fuel bridges.


9. Fit new O-rings on the fuel bridges and slide them into the cylinder head.

10. Fit a socket with extension piece on the bolts of the fuel bridges and tighten by hand. Then use a ratchet handle and tighten a further 360°.

11. Lubricate the sliding surfaces on the camshaft and valve bridges.


12. Position the camshaft and lay the camshaft bearing caps in their respective positions.

13. Apply sealing compound 87 81 841 on the 5th camshaft bearing cap sealing surfaces, see illustration.

14. Tighten the camshaft bearing cap bolts in stages, 0.5-1 turn in a spiral formation starting with cap number 3.

Tightening torque: 20 Nm (15 lbf ft).

15. Fit the coolant temperature sensor and refit the thermostat housing.


16. Clean off gasket remains from the sealing surfaces on the cylinder head.

17. Put a new gasket on the cylinder head and fit the lower part of the intake manifold with new bolts.

Tightening torque: 20 Nm (15 lbf ft).

18. Fit a new gasket on the lower part of the intake manifold and fit the upper part.

Tightening torque: 22 Nm (16 lbf ft).

19. Fit the glow plugs.

Tightening torque: 10 Nm (7.5 lbf ft).

20. Clean the sealing surfaces and fit the exhaust manifold to the cylinder head with a new gasket and new nuts.

Tightening torque: 22 Nm (16 lbf ft).

21. Refit the generator bracket with a new gasket.

Tightening torque: 20 Nm (15 lbf ft).

22. Fit the lifting eyes.

23. Fit the cylinder head, see