Cylinder Head Assembly

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:





Cylinder head bolts
1st stage 30 Nm
2nd stage 60 Nm
3rd stage 90° (1/4 turn) further
4th stage 90° (1/4 turn) further

Cylinder head Flatness
Maximum permissible distortion 0.1 mm





Intake manifold to cylinder heads 10 Nm





Camshaft Bearing cap to cylinder head 5 Nm +90° (1,2)

1) Replace bolts
2) 90° corresponds to one quarter-turn

Exhaust manifold to cylinder head 25 Nm 1)

Tighten exhaust manifold bolts diagonally starting from the center

1) Replace nuts

Camshaft sprocket to camshaft 55 Nm