Cylinder Head, Removing and Installing (Overview)

Cylinder head, removing and installing

Note:
• Always replace cylinder head bolts when assembling.
• Replace self - locking nuts.
• Always replace bolts that are tightened to a specified angle.
• Always replace sealing rings and gaskets when assembling.
• When installing an exchange cylinder head with the camshafts the contact surfaces between valve lifter and cam running surface must be oiled after installation of the cylinder head.
• The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head.
• When fitting a new cylinder head or cylinder head gasket, drain off all the old coolant and re-fill with new coolant.
• Cylinder heads, which have cracks between the valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.3 mm in width, or when no more than the first 4 turns of the spark plug threads are cracked.

Removing and installing toothed belt, Service and Repair
Checking cylinder compression, Compression Check




1 - Cylinder head
- If replaced, replace the coolant completely.
- Removing cylinder head, Removing Cylinder Head
- Installing cylinder head, Installing Cylinder Head
- Checking for distortion, Refer to Fig. 1
- Reworking limit, Refer to Fig. 2
2 - Oil deflector
- Note installation position: above intake camshaft between No. 1 and No. 2 cylinders
3 - Cylinder head bolt
- Replace
- Note sequence when loosening, Removing Cylinder Head
- Note sequence when tightening, Installing Cylinder Head
4 - Cylinder head cover gasket
- Replace if damaged or leaking
- Before fitting gasket, apply sealant D 454 300 02 to sides of sealing surfaces:
- Between double bearing cap and cylinder head, Refer to Fig. 3
- Between hydraulic chain tensioner and cylinder head, Refer to Fig. 4
5 - Cylinder head cover
6 - Gasket
- For ignition coil
- Replace if damaged
7 - Ignition coil
- Testing
8 - 10 Nm
9 - Filler cap
10 - Seal
- Replace if damaged
11 - 10 Nm
12 - Intake manifold gasket
- Replace
13 - Cylinder head gasket
- Removing cylinder head, Removing Cylinder Head
- Position: Part No. toward cylinder head
- If replaced, replace the coolant completely.





Fig. 1 Checking cylinder head for distortion
- Use knife-edge straightedge and feeler gauge to measure at several points.
- Maximum permissible distortion: 0.1 mm





Fig. 2 Cylinder head reworking limit
Reworking the cylinder head (shaving) is only permitted down to minimum dimension -a-.
Minimum dimension -a- = 139.25 mm





Fig. 3 Sealing transition points between double bearing cap and cylinder head
- Carefully apply a thin coat of sealant "D 454 300 02" to both edges of sealing surfaces between double bearing cap and cylinder head -arrows- using a small screwdriver.





Fig. 4 Sealing points: hydraulic chain tensioner/ cylinder head
- Carefully apply a thin coat of sealant "D 454 300 02" to both edges of sealing surfaces between hydraulic chain tensioner and cylinder head -arrows- using a small screwdriver.