Cylinder Head, Installing

Cylinder head, installing

Note:
^ Always replace cylinder head bolts when assembling.
^ Replace self-locking nuts and bolts, when performing repairs.
^ Replace bolts which have a specified tightening angle as well as seals and gaskets.
^ If repairing, carefully remove any remains of gasket material from cylinder head and cylinder block. Make sure that no long scores or scratches are made on surfaces.
^ Carefully remove any remaining emery and abrasive material.
^ No oil or coolant must be allowed to remain in blind holes for cylinder head bolts in cylinder block.
^ When installing an exchange cylinder head with camshafts installed, contact surfaces between roller rocker fingers and cam running surface must be oiled after installation of cylinder head.
^ Plastic protectors installed to protect open valves should not be removed until cylinder head is ready to be installed.
^ When installing a new cylinder head or cylinder head gasket, drain off all old coolant and re-fill with new coolant.
^ Cylinder heads must not be reworked (machined).
^ Cylinder heads which have cracks between valve seats or between valve seat inserts and spark plug thread can be used further without reducing service life, provided cracks do not exceed a maximum of 0. 3 mm in width, or when no more than first 4 turns of spark plug threads are cracked.
^ Remove new cylinder head gasket from packaging just before installation.
^ Handle gasket extremely carefully. Damaging silicone layer or indented area will lead to leaks.
^ Position cylinder head gasket on dowel pins. The word "oben" (top) or Part No. should face towards cylinder head.
^ Secure all hose connections with correct hose clamps (same as original equipment), Refer to Parts Supplier.
^ After working on valve gear, turn engine carefully at least 2 rotations to ensure that none of the valves make contact when starter is operated.
^ All cable ties which are opened or cut open on removal must be replaced in same position when installing.

- Turn crankshaft and camshafts to TDC of cylinder No. 5 before installing cylinder head:





^ Larger holes (arrows) in securing plates on camshaft sprockets should point inward...





^ ...and clamping bolt 3242 must be screwed in.





^ Place cylinder head gasket in position.
^ Note position of dowel sleeves -arrows- in cylinder block.
^ Check installation position of cylinder head gasket- the word "oben" (top) or Part No. should face toward cylinder head.

- Place cylinder head on.
- Insert new cylinder head bolts and screw in hand-tight.





- Tighten cylinder head bolts in four stages in sequence shown as follows..
- Tighten using torque wrench:
^ 1st stage - 30 Nm
^ 2nd stage - 60 Nm

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

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

Remaining installation steps are carried out in reverse sequence - note following points-.
- Install cylinder head cover.
- Install combination valve for secondary air system (right side).
- Install exhaust manifold.
- Install front exhaust pipe.
- Install rear coolant pipe.
- Install coolant pipe on cylinder head.
- Install front coolant pipe.
- Install intake manifold.
- Install toothed belt (adjust valve timing).

Note: After working on valve gear, carefully turn over engine at least two full revolutions by hand to ensure that none of the valves makes contact when starter is operated.

- Install engine.
- Fill cooling system with fresh coolant.





Tightening torques