Cylinder Head, Removing and Installing

Cylinder head, removing and installing

Note:
- Replace cylinder head bolts.
- Always replace self-locking nuts, bolts as well as gaskets and O-rings.
- After installing a replacement cylinder head with camshafts attached, grease contact surfaces between valve lifters and cam lubricating surfaces.
- Do not remove plastic covers protecting exposed valves until immediately before installing cylinder head.
- When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.
- Cylinder heads with small cracks between the valve seats that are less than 0.3 mm (0. 0.12 inch) wide and/or between one valve seat and only the first 4 threads of the spark plug thread, can continue to be used without reduced service life.





Part I
1 - Cylinder head gasket
- Replacing, [1][2]Cylinder Head, Removing
- Installed position: part number faces cylinder head
- After replacing, replace coolant
2 - Cylinder head
- Removing, [1][2]Cylinder Head, Removing
- Check for distortion, Refer to Fig. 1
- Refacing measurement, Refer to Fig. 2
- Installing, [1][2]Cylinder Head, Installing
- After replacing, replace coolant
3 - Oil deflector
- Verify correct installation position above intake camshaft between cylinders 1 and 2
- Cylinder head bolt
- Always replace
- Follow sequence of removal, [1][2]Cylinder Head, Removing
- Follow torque sequence, [1][2]Cylinder Head, Installing
5 - Gasket
- For ignition coil
- Replace if damaged
6 - Ignition Coil
- Check
7 - Bolt
- 10 Nm (7 ft. lbs.)
8 - Oil filler cap
9 - Gasket
- Replace if damaged or leaking
10 - Nut
- 10 Nm (7 ft. lbs.)
11 - Cylinder head cover
- Removing and installing, Service and Repair
12 - Cylinder head cover gaskets
- Replace if damaged or leaking
- Before installing, seal contact surfaces with sealant D 454 300 A2 Refer to Fig. 3 and Fig. 4

CAUTION! Part numbers are listed here for reference only. Always check with your Parts department for the latest information.

13 - Coolant flange With coolant temperature sensor
14 - Bolt
- 10 Nm (7 ft. lbs.)
15 - O-Ring
- Always replace





Part II
1 - Gasket Always replace
2 - Nut
- 10 Nm (7 ft. lbs.)
3 - Sockethead bolt
- 10 Nm (7 ft. lbs.)
4 - O-Ring For injector
- Always replace
5 - Fuel rail
- With injectors
6 - Upper coolant line
7 - Sockethead bolt
- 10 Nm (7 ft. lbs.)
8 - Bolt
- 10 Nm (7 ft. lbs.)
9 - O-Ring
- For upper coolant line Always replace
10 - Sockethead bolt
- 10 Nm (7 ft. lbs.)
11 - Intake plenum Removing and installing, Service and Repair
12 - Sockethead bolt
- 20 Nm (15 ft. lbs.)
13 - Brace
- For intake manifold





Fig. 1 Check cylinder head for distortion
- Using straightedge and feeler gauge, check cylinder head for distortion at multiple points.
Cylinder head distortion must not exceed 0.1 mm (0.004 inch)





Fig. 2 Refacing cylinder head
Refacing cylinder head can only be done to a minimum dimension -a-.
Minimum dimension -a-: 139.25 mm (5.482 inch)





Fig. 3 Sealing contact surfaces between double bearing cap and cylinder head
- Using small screwdriver, carefully apply thin layer of sealant D 454 300 A2 to both corners of sealing surface between double bearing cap and cylinder head (arrows).





Fig. 4 Sealing contact surfaces between hydraulic chain tensioner and cylinder head
- Using small screwdriver, carefully apply thin layer of sealant D 454 300 A2 to both corners of sealing surface between hydraulic chain tensioner and cylinder head (arrows).