21: Component replacement, D4192T3 Page 1 of 7

21: Component replacement, D4192T3

V40 (-04), 2001, D4192T3, M56, R.H.D

5/1/2014 PRINT
21: Component replacement, D4192T3
Installing the
cylinder head
Special tools:
999 5812
999 5811
999 9684
951 2050
999 5199
951 2797
998 5496

Preparations

Clean the gasket surface on
the cylinder head and block

Remove any oil and dirt from
the holes for the screws.

Measuring the
piston protrusion

Caution! The
protrusion of the
piston must be
measured from the
front to the rear of
the engine.

Clean the top of the piston on
the first cylinder

Turn the crankshaft in the
direction of engine rotation, to
just before the ignition position
for the piston

Position special tool 999 5812
on the block, beside the piston

Install special tool 999 5811
with dial gauge 999 9684 in
place

Reset the dial test indicator
against the cylinder block.
Set the piston to the ignition
position. Slide the dial gauge
over the edge of the piston.

Note! The measurement

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must not be taken at the

valve opening.

Maximum piston protrusion:

0.56 ±0.06 mm.
Installing the
cylinder head
gasket
Place the new gasket on the
cylinder block over the locating
pins on the cylinder block.

Installing the
cylinder head

Turn the crankshaft until the
piston in cylinder 1 has
passed top dead center
(TDC) by 1/4 of a turn

Align the cylinder head over
the guide sleeves.

Installing the
cylinder head
screws

Note! For all work

where the cylinder
head has been
removed, new
cylinder head
screws must be
installed.

Lubricate the
threads for the
cylinder head
screws and the
mating
surfaces

Install the
screws.
Tighten the
screws by
hand.

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Tighten the cylinder head screws in

two stages. The cylinder head
screws do not require post-
tightening.

Step 1

Tighten to 30 Nm

Angle-tighten 100° ±4° in
one movement. Use tool 951
2050 .

Then wait at least three

minutes to allow the cylinder head
gasket to stabilize.

Step 2

Slacken off screws 1 and 2
completely

Tighten screws 1 and 2.
Tighten to 25 Nm

Angle-tighten 213° ±7° in
one movement. Use tool 951
2050 .

Repeat Stage 2 for the remaining

screws, in order 3-4, 5-6, 7-8 and
9-10 as illustrated.
Installing the
turbocharger (TC)

Install the
turbocharger
(TC). See
Replacing the
turbocharger
(TC):Installing
the
turbocharger
(TC) .
Installing the fuel
injection pump

Position the fuel pump and
bracket and the holder for
the engine mounting.

Install

the 3 screws for the holder
for the engine mounting

the 2 screws holding the
bracket for the fuel pump
against the engine

the ingoing fuel line to the
fuel injection pump

the delivery line between the
fuel injection pump and the
fuel pipe

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the clamps for the fuel lines

from the fuel injection pipes.
Other installing

Install the vacuum hoses
from the vacuum pump.

Install

the mounting
for the pipe for
the power
steering pump
on the holder
for the engine
mounting

the fuel
temperature
sensor

the fuel
temperature
sensor cable
for the fuel
injection
pump.

Position the cable

harness.

Install the
connectors on

the back-up
(reversing)
lamp switch

the EGR valve

the stop
shutter
solenoid

the camshaft
position (CMP)
sensor

the injectors

the glow plugs

the fuel
pressure
sensor

the fuel
injection pump

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the fuel
temperature
sensor

the oil
pressure
sensor

the generator
(GEN)

the air
conditioning
(A/C)
compressor

the engine
speed (RPM)
sensor.

Location of
components in the
engine compartment,
see Engine
compartment .

Installing the
thermostat
housing

Position the thermostat
housing and tighten.

Installing the
camshaft pulley

Install

the plate
behind the
camshaft
pulley

the camshaft
pulley. See
Replacing the
gear wheel and
the oil seal
rings on the
timing belt
side:Installing
the gear wheel
for the
camshaft . Use
counterhold

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999 5199 .
Installing the
timing belt

Install the
timing belt,
see Replacing
the timing
belt:Installing
the new timing
belt .
Adjust the belt
tension. Use
tool 951 2797

Remove the
jack.
Filling with coolant

Fill with coolant. See Draining
and filling the cooling
system:Filling and bleeding
the cooling system .

Checking the
cooling system for
leaks

Check that the cooling system
is not leaking. See Draining
and filling the cooling
system:Checking for leakage
in the cooling system . Use
pressure tester 998 5496 .

Installing the
mounting for the
engine control
module (ECM)

Install the
mounting for the
engine control
module (ECM).
See Engine control
module (ECM),
replacing:Installing
engine control
module bracket .

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Finishing

Install

all splash guards

the connector for
the boost
pressure sensor

the air intake
hose

the upper charge
air cooler pipe

the battery
negative lead.
See Note when
disconnecting
and connecting
the battery
lead:Installation .

Start the engine.

Check that there is
no leakage.
Read off and erase
diagnostic trouble
codes (DTCs).
Install the engine
cover.

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