21: Cylinder head, D5244T Page 1 of 23

21: Cylinder head, D5244T

V70 (00-08), 2002, D5244T, M56, YV1SW793222257186, 257186

28/12/2010 PRINT
21: Cylinder head, D5244T
Cylinder
head/gasket,
replacing
Special tools:
999 5199
951 2050
951 2767
999 7005
999 7006
999 7007
999 7010
999 7015

Removing the
cylinder head

Note! The
illustrations in this
service
information are
used for different
model years
and/or models.
Some variation
may occur.
However, the
essential
information in the
illustrations is
always correct.
Safety

Caution! FIRE
RISK. Take great
care to avoid
causing sparks and
fuel leakage when
working on the
fuel system.

First see Safety

regulations for
handling fuel .

Remove the cable

from the battery
negative terminal.
First read Battery,
disconnecting .

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Preparation

Remove:
„ the radiator breather tube
from the expansion tank.
Install lock grip pliers
„ the expansion tank cap
„ the right front wheel
„ the plastic nuts on the cover
at the right wing liner.

Draining coolant

Raise the car. Remove the splash

guard from under the engine.
Thread a hose onto the drain
cock.
Open the drain cock on the
engine.
Drain the coolant into a container.
Close the nipple.
Remove the hose.

Separating the
exhaust system

Remove:
„ the nuts at the junction of the
turbocharger and front
exhaust pipe. Use rust-
proofing agent
„ the screw for the front
exhaust pipe and support
bracket.

Remove the pipe from the

turbocharger (TC). Put the pipe to
one side.
Removing the
turbocharger
(TC)/manifold

Slacken off the hose

clamp for the charge
air hose for the
turbocharger (TC).
Push the hose to one
side.

Remove:
„ the oil

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drainage pipe
„ the grommet
from the block
„ the clamp
holding the oil
pressure pipe
to the coolant
pipe
„ the vacuum
hose to the
variable nozzle
turbo
governor.

Remove:
„ the tie strap
for the servo
hose from the
engine
stabiliser brace
„ the cross stay
between the
suspension
turrets
„ the engine
cover by
pulling it
straight up
„ the pipe
screws for the
turbocharger
(TC) oil
pressure pipe
„ the screw for
the charge air
pipe in the
vacuum pump.
Slacken off the
hose clamp for
the intake hose
for the
turbocharger
(TC). Push the
hose to one
side
„ the screws for
the exhaust
gas
recirculation
(EGR) pipe
connection to
the exhaust
gas
recirculation
(EGR) valve
„ the nuts for
the exhaust
manifold. Use

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rust-proofing
agent
„ the exhaust
manifold and
turbocharger
(TC). Slowly
lower the unit
onto the drive
shaft and
steering gear
„ the screw that
holds the
coolant pump
inlet pipe onto
the cylinder
block.
Position the
engine according
to the marking

Remove:
„ the timing belt
cover
„ the servo
reservoir. Lift
up and place
on top of the
engine.

Warning! Ensure
that no power
steering fluid is
spilled.

Turn the crankshaft clockwise

until the markings on the
crankshaft and camshaft pulley
correspond.
The markings are illustrated.

Disconnecting the
belt tensioner

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Slacken off the centre screw for

the belt tensioner slightly.
Turn the tensioner eccentric using
a 6 mm Allen key. Turn clockwise
to 10 o'clock.
Unhook the timing belt from the
timing gear pulley.

Removing the
timing gear pulley

Remove:
„ the screws. Use counterhold
999 5199 .
„ the timing gear pulley
„ the two screws for the inner
timing belt cover
„ the idler pulley.

Removing the air

cleaner (ACL)
housing

Remove:
„ the fresh air intake for the
air cleaner (ACL) housing
„ the solenoid valve
„ the clips for the cable
harness from the air cleaner
(ACL) housing
„ the connector from the mass
air flow (MAF) sensor.

Disconnect the hose for the mass

air flow sensor at the charge air
pipe. Remove the air cleaner (ACL)

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housing assembly.

Remove:
„ the connector and positive
power supply in the central
electrical unit
„ the two screws for the
central electrical unit and lift
to one side.
Removing
components

Remove:
„ the coolant hose from the
thermostat housing
„ the support for the power
steering pump against the
cylinder head
„ the rear / upper engine
mounting bracket
„ the intake hose between the
exhaust gas recirculation
(EGR) mixer and intake
„ the crankcase ventilation pipe
hose from the flame trap
„ the two screws from the
bracket for the crankcase
ventilation pipe
„ the connector from the
solenoid valve on the air filter
housing
„ the charge air pipe assembly
with the crankcase ventilation
hose.

Disconnect the return hose from

the injectors.
Remove the crankcase ventilation
hose from the valve cover.
Exposing the cable
harness

Disconnect the connectors

from:
„ the injectors
„ the camshaft position (CMP)
sensor
„ exhaust gas recirculation
(EGR) actuator
„ the fuel control valve
„ the glow plugs
„ the fuel pressure sensor
„ the variable nozzle turbo
governor
„ the engine coolant
temperature sensor.

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Remove the screws

for the cable duct
over the engine.
Place the cable
harness to one side.

Removing the fuel

injection pump

Caution! Plug all the holes to

prevent dirt from entering.

Remove:
„ the delivery line. Plug the
pipes
„ the suction and return hose
„ the three mounting screws
for the injection pump
„ the fuel injection pump.

Caution! Do not turn the pump

when it is removed. It is
important that it is in the same
position when reinstalled.
Removing the
vacuum pump

Caution! Risk of oil leakage.

Use paper as an underlay.

Remove:
„ both the vacuum pump
hoses
„ the vacuum pump screws
„ the vacuum pump.

Caution! Handle the vacuum

pump carefully. If a pump has
been dropped onto the floor it
must never be reinstalled.
Disconnecting the
exhaust gas
recirculation (EGR)
cooler

Disconnect the hose

from the charge air
cooler (CAC) at the
mixer. Remove the
three mounting
screws for the
exhaust gas
recirculation (EGR)
cooler. Gently lower
the exhaust gas

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recirculation (EGR)
cooler onto the
gearbox.

Removing the fuel

rail and injectors

Note! Use paper to collect any

spilled fuel.

Remove:
„ the return hose from the
engine return pipe
„ the delivery line
„ the fuel rail
„ the injectors. Counterhold the
delivery line terminal in the
nozzle (1) when removing
„ the screws for the mountings
for the fuel rail on the
cylinder head.

Caution! Do NOT counterhold

the injector cap nuts (5).
Removing the
cylinder head

Remove:
„ the intake /
camshaft cover
„ rear oil seal
cap / pump
bracket.
Removing the
camshafts and
bearing cap

Caution! Check the

markings on the
bearing caps
carefully to
prevent incorrect
reinstallation.
Incorrect
reinstallation
could lead to
engine seizure.

Slacken off the

retaining screws for
the camshaft covers
from the outside to
the middle. Do not
remove any of the
screws.
Remove the front

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cover on the intake

camshaft.
Slacken off each
screw one turn at a
time. Carefully
release the
camshaft.
When the camshaft
is no longer under
tension, remove all
the screws and
remove the bearing
caps.

Place the camshaft covers on a

clean, dry surface (dry paper for
example).
Carry out the same operation on
the other camshaft.

Caution! Check the markings

on the bearing caps carefully to
prevent incorrect
reinstallation. Incorrect
reinstallation could lead to
engine seizure.
Marking up and
removing rocker
arms

Remove and mark the rocker

arms as follows: Intake: i1, i2, i3
etc. Exhaust: e1, e2, e3 etc. Place
the rocker arms on a clean, dry
surface (paper cloths for
example).

Note! The rocker arms can

separate.

Removing the
cylinder head

Slacken off the

screwed joint for the
cylinder head.
Start at the ends and
work alternately
towards the centre.
Lift out the cylinder
head.
Place the cylinder
head upside down on
a clean, dry
absorbent covered
(paper cloths for

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example) surface.
This is to prevent
damage to the
gasket surface of
the cylinder head.

Remove the cylinder head gasket.

Check and note the marking
(number of holes).

Caution! Do not damage the

gasket mating surfaces. The
cylinder head gasket has very
little chance of sealing any
damage to the gasket mating
surface.

Replacing the
cylinder head

Remove:
„ the thermostat
housing
„ the glow plugs.

Caution! To
prevent
damage to
the glow
plugs, they
must be
tightened to
the correct
torque. See
Tightening
torque .

Caution! Do not
damage the
mating surfaces.
Cleaning the
gasket faces

Clean the
gasket faces
for:
„ the manifold
Check that the
stud threads
are
undamaged
and are
tightened
„ the coolant
bypass channel
„ the thermostat
housing

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„ the cylinder
block
„ camshaft
cover.

Blow the oil and

water ducts clean.

Caution! Use a
razor blade or a
gasket scraper and
gasket solvent
1161 440.

Warning! Use a
fume hood or
extractor when
using gasket
solvent!
Installing the
cylinder head

Caution! For
tightening torques
not in the text, see
Tightening torque .
Aligning the
crankshaft

Remove:
„ starter motor
„ the blind cover plug.

Turn the crankshaft clockwise

slightly.
Install crankshaft adjustment tool
999 7005 .
Ensure that it bottoms out against
the cylinder block.
Turn the crankshaft counter-
clockwise until it stops against the
crankshaft stop.
Check that the marking on the
crankshaft timing gear pulley
corresponds with the marking on
the oil pump.
Replacing the
cylinder head

Install:
„ thermostat
housing. Use a
new gasket
„ the glow plugs.

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Caution! Handle
the cylinder head
carefully so that
the gasket faces
are not damaged.
Selecting the
correct thickness
for the cylinder
head gasket

Use a gasket with same marking

(number of holes) as before.
The cylinder head gasket is
available in five thicknesses,
marked by holes.
The gasket thickness depends on
the piston height above the
cylinder block.

Installing the
cylinder head

Install the new

cylinder head gasket.
Install the cylinder
head.
Use new screws.
Lubricate and install
all the screws.
Tighten the screws in
the following order.
Tighten the screws
alternately from the
centre and outwards.

1. 20 Nm
2. Remove
3. 20 Nm
4. 50 Nm
5. 90 degrees.
Use protractor
951 2050 .
6. 90 degrees
Installing tappets
and rocker arms

Lubricate the
tappets. Install the
tappets in the
marked order.
Check that the
tappets are correctly

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positioned against
the valve stems.

Installing
camshafts and
camshaft covers

Clean and check that there is no

dirt in the bearing positions on the
camshaft, cylinder head and
camshaft cover.

Lubricate using engine oil.

Lubricate:
„ the camshaft bearing
positions and lobes
„ the cylinder head bearing
positions
„ the camshaft cover
„ the rollers for the rocker
arms.

Position the camshafts with the

markings on the camshaft pulleys
opposite each other.

Install the camshaft covers. Screw

in the screws until the covers lie
flat against the camshaft.
Wait to install the front cap on the
intake camshaft.
It will be installed later.

Carefully screw the screws into

place one revolution at a time,
until the camshaft is secured in the
bearing positions in the cylinder
head.
Carry out the same procedure with
the other camshaft.

Tighten the screws for both

camshafts. Tighten to 10 ±2 Nm.
Installing the
camshaft
adjustment tool

Use camshaft tool 999 7007 .

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Caution! The camshafts must

not be turned more than is
absolutely necessary to install
the camshaft adjustment tool.
The valves may be damaged.

Carefully turn the camshafts using

a screwdriver in the groove for the
high pressure pump and vacuum
pump in the camshaft so that the
camshaft adjustment tool can be
installed.
Install the camshaft adjustment
tool.
Installing the front
and rear caps

Warning! Use a
fume bonnet or
extractor when
using gasket
solvent.

Caution! Use a
razor blade or a
gasket scraper and
gasket solvent
1161 440.

Wipe the mating

surfaces of the
bearing caps and the
corresponding
surfaces on the
cylinder head dry.
Apply liquid gasket
11 61 059 to the
bearing cap.
The surface must be
completely covered
without any excess.
Use roller 951 2767 .
Lubricate the bearing
race for the front
bearing cap using
engine oil.
Install the cap.
Tighten to 10 Nm.

Installing the
valve cover

Check that the

camshafts lobes are
covered by a film of
oil.
Lubricate if

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necessary. Use
engine oil.

Wipe the gasket

surfaces dry.
Position the valve
cover gaskets. Check
that the gaskets are
correctly seated in
their grooves and
are not twisted.
Carefully position the
valve cover. Do not
damage the gaskets.
Install the screws.
Tighten the screws.
Torque the screws.

Installing the front

camshaft seal

Use tool 999 7006 .

Lubricate the surface of the seal
that the camshaft rotates against.
Press in until the drift bottoms
out.

Installing toothed
belt

Install:
„ the 2 screws for the inner
timing belt cover
„ the idler pulley. Tighten to
25Nm
„ the timing gear pulley, using
three screws until they just
affect the pulleys
„ the timing belt.

Caution! Check that the timing

gear pulley screws are not in
the limit position in the oval
holes. See the illustration.
Tighten the timing
belt

This adjustment is to be made

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with a cold engine.

A suitable temperature is
approximately 20°C.
At a higher temperature, for
example with a warm engine or a
higher ambient temperature, the
needle is further to the right.
The illustration shows the position
of the indicator when aligning the
timing belt tensioner at different
temperatures.

Tension the timing

belt as follows:
„ Tighten the
belt tensioner
centre screw.
Tighten to 5
Nm. Turn the
belt tensioner
eccentric
counter-
clockwise until
the tensioner
indicator
passes the
marked
position.
Then turn the
eccentric back
so that the
indicator
reaches the
marked
position in the
centre of the
window
„ Hold the
eccentric
secure and
tighten the
centre screw.
Tighten to 27
Nm. Check
that the
indicator is in
the correct
position.

Check that the

timing gear pulley
screws are not in the
limit position in the
oval holes.
Install the last screw
on the camshaft
pulley. Tighten all
the screws. Tighten

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to 30 Nm. Use
counterhold 999
5199

Remove:
„ camshaft adjustment tool
using tool 999 7007
„ crankshaft adjustment tool
using tool 999 7005 .

Install the blind

cover plug with a
new sealing washer.
Tighten to 40 Nm.
Install the starter
motor.

Check

Checking the marking

„ press the belt to check that
the indicator on the tensioner
moves easily
„ turn the crankshaft 2 turns.
Check that the markings on
the crankshaft and camshaft
pulley correspond
„ check that the indicator on
the belt tensioner is within
the marked area.

Install:
„ the timing belt cover
„ the auxiliaries belt
„ the expansion tank and the
bleed hose to the expansion
tank
„ the servo reservoir.
Installing injectors

Note! For
tightening torques,
see Tightening
torque .

Caution! Cleaning the nozzle

seats. Blow clean the nozzle
seat using compressed air. Use
tool 999 7009 . Ensure that the

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end of the tool is clean. Rotate

with the pole a few times until
the surface for the seal washer
is completely free of carbon.
Blow clean regularly and check
for cleanliness.

Caution! When installing

injectors, new or old, new
tension mounting yokes,
washers, screws and clips must
be used. Install the injector
with new seal washers and
screws. Tighten. See .

Note! Plug the inlets and

outlets if returning or re-using
the fuel injectors.

Remove:
„ the snap ring (3). Use tool
999 7015
„ the shim (2)
„ the tensioned mounting
yokes (6).

Note! Clean the area around

the injectors and the delivery
line terminals before installing.

Install:
„ a new tensioned mounting
yoke. Lock the shim using a
new snap ring. Use tool 999
7015
„ injectors with new seal
washers (4) and screws (7).
Use tool 999 7010 to guide
the injectors into the correct
position. Tighten the
injectors. Tighten to 10 Nm.
Start with cylinder 3. Then 2,
4, 1, 5.

Tighten the valve cover screws.

Tighten to 10 Nm. Start in the
centre and continue outwards.
Then post-tighten the injectors.
Tighten to 10 Nm.
Installing the fuel
rail

Install:
„ the screws for
the mountings
for the fuel rail
on the cylinder
head.

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„ the fuel rail

„ new delivery
lines. Tighten
to 28 Nm.
Counterhold
the delivery
line terminal in
the nozzle (1)
when
tightening
„ the return hose
from the
engine return
pipe. Clamp
using new
clamps.

Caution! Do NOT
counterhold the
injector cap nuts
(5).
Installing the
exhaust gas
recirculation (EGR)
cooler

Install:
„ Exhaust gas
recirculation
(EGR) cooler.
Tighten
„ the hose from
the charge air
cooler (CAC)
on the mixer.
Installing the
vacuum pump

Install:
„ the vacuum pump. Use new
O-rings. Tighten to 17 Nm
„ both the hoses for the
vacuum pump.

Caution! Handle the vacuum

pump carefully. If a pump has
been dropped onto the floor it
must never be reinstalled.

Installing the fuel

injection pump

Install:
„ the fuel injection pump.
Tighten to 17 Nm
„ new delivery line .
„ the suction pipe and return

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line with new clamps.

Installing the
cable harness

Position the cable harness over the

engine. Screw the cable duct into
place. Install the connectors for:

„ the injectors
„ exhaust gas recirculation
(EGR) actuator
„ the fuel control valve
„ the glow plugs
„ the fuel pressure sensor
„ the variable nozzle turbo
governor
„ the engine coolant
temperature sensor.
Installing
components

Install:
„ the rear / upper engine
mounting bracket
„ the return hose for the
injectors
„ the crankcase ventilation
hose on the valve cover
„ the charge air pipe assembly
with the crankcase ventilation
hose
„ the connector for the solenoid
valve
„ the screw for the bracket for
the crankcase ventilation pipe
„ the hose for the crankcase
ventilation pipe on the flame
trap
„ the intake hose between the
exhaust gas recirculation
(EGR) mixer and intake
„ the support for the power
steering pump against the
cylinder head
„ the engine coolant hose on
the thermostat housing

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„ the screw for the charge air

pipe in the vacuum pump. Do
not tighten!
Installing the air
cleaner (ACL)
housing/central
electrical unit

Install:
„ the two screws for the
central electrical unit
„ the connector and positive
power supply in the central
electrical unit
„ air cleaner (ACL) housing
„ the hose for the mass air
flow (MAF) sensor on the
charge air pipe
„ the connector for the mass
air flow (MAF) sensor
„ the solenoid valve and cable
harness clip in the air cleaner
(ACL) housing
„ the fresh air intake for the
air cleaner (ACL) housing
Installing
components

Install:
„ the screw that holds the
coolant pump inlet pipe onto
the cylinder block.
„ the exhaust manifold and
turbocharger (TC) using a
new gasket. Use new nuts.
Tighten to 30 Nm
„ the screws for the exhaust
gas recirculation (EGR) pipe
connection to the exhaust gas
recirculation (EGR) valve
„ the inlet hose for the
turbocharger (TC). Tighten
the clamp
„ the front exhaust pipe in the
turbocharger (TC) using new
nuts and a new gasket
„ the upper pipe screw for the
turbocharger (TC) oil
pressure pipe. Do not tighten.
Use new seal washers.
Tighten the screw for the
charge air pipe in the vacuum
pump.
Installing
components
underneath the car

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Install:
„ the lower pipe
screw in the
block for the
oil pressure
pipe. Tighten
to 38 Nm
„ the clamp
holding the oil
pressure pipe
to the coolant
pipe
„ the vacuum
hose on the
variable nozzle
turbo governor
„ the oil
drainage pipe.
Use a new
grommet and
gasket
„ the charge air
hose for the
turbocharger
(TC). Tighten
the clamp
„ the screw for
the front
exhaust pipe
and support
bracket
„ the plastic nuts
on the cover at
the right wing
liner.
„ the right front
wheel. See
Installing
wheels .
„ the splash
guard under
the engine
„ the battery
negative lead.
Also read
Battery,
disconnecting .
„ Tighten the oil
pressure pipes
in the
turbocharger
(TC). Tighten
to 18 Nm
„ the engine
cover
„ the cross stay
between the

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suspension
turrets
„ the tie strap
for the servo
hose from the
engine
stabiliser brace
Check

Replace the oil and

oil filter. See Oil/oil
filter, replacing .

Check:
„ the engine oil
level
„ the servo oil
level
„ the coolant
level.

Function test
Run the engine at
fast idle speed until
the thermostat
opens.
Ensure that the
heater control in the
passenger
compartment is at
the maximum
position.
Check the engine for
leaks.
Top up the coolant if
necessary.

28/12/2010 PRINT

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