Cylinder Head, Installing

CAUTION!
- DO NOT re-use fasteners that are worn or deformed in normal use.
- Some fasteners are designed to be used only once and are unreliable and may fail the second time. Always replace fasteners with new parts where indicated and any other time when deemed necessary by inspection.
- To prevent contact corrosion, use only approved fasteners. They have a special green color coating.

Notes:
- Replace cylinder head bolts.
- Remove old sealer carefully to avoid long scratches.
- Remove all grinding compound.
- Remove all oil or coolant from cylinder head bolt holes in crankcase.
- Handle gaskets carefully. Damage to silicone parts of gaskets can cause leaks.
- Place cylinder head gasket on spacer sleeves. Marking on gasket "Open" (top) or part number must face cylinder head.
- After completing repairs do not start engine before turning crankshaft carefully for two full revolutions to avoid valves from contacting Pistons.

- Install cylinder head in reverse order of removal but note the following:
- Note identification markings on cylinder head gasket. "Open" (top) or part number must face cylinder head
- Install cylinder head.
- Insert cylinder head bolts and tighten by hand.





- Tighten cylinder head bolts in four stages in sequence shown as follows:
- Tighten with torque wrench:
- 1st stage: 35 Nm (26 ft. lbs.)
- 2nd stage: 60 Nm (44 ft. lbs.)

- Tighten with normal fixed wrench:
- 3rd stage: 1/4 turn (90°) further
- 4th stage: 1/4 turn (90°) further

Note: It is not necessary to re-tighten cylinder head bolts after repairs have been performed.





- To replace gaskets for intake manifold, remove bolts -1-. Tightening torque 0.6 Nm (5 inch lbs.).
- Locating stud for intake manifold -2-; tightening torque 7 Nm. (62 inch lbs.)

Note: Replace cylinder head cover gaskets if damaged.





- Apply a small amount of sealant D 545 300 A2 to sealing points -arrows- on upper surface of cylinder head.
- Tighten bolts for cylinder head cover crosswise and in stages.
- Install toothed belt on camshafts.

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

Tightening Torques (Part 17 Of 18):

Tightening Torques (Part 18 Of 18):

Tightening Torques