Cylinder Head, Installing

Cylinder head, installing

Note:
^ Always replace cylinder head bolts.
^ Replace self-locking nuts and bolts when performing repairs.
^ Replace bolts tightened by turning through a specified angle as well as oil 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 aft old coolant and re-fill with new coolant.
^ 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 (top) or Part No. should face toward cylinder head.
^ Secure aft hose connections with correct hose clamps (same as original equipment) See parts catalog.
^ 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.

- Check whether camshafts of both cylinder heads are at TDC.





^ Slots (arrows) at front of camshafts must be parallel to and on a level with top edge of cylinder head ...





^ ... and locating bolt 3242 must be in position.





- Install cylinder head gasket.
^ Pay attention to dowel sleeves (arrows) in cylinder block
^ Pay attention to installation position of cylinder head gasket; "top" mark/part number must face cylinder head
- Install cylinder head.
- Insert and hand-tighten new cylinder head bolts.





- Tighten cylinder head as follows in four stages in sequence shown.
- Use torque wrench to tighten:
^ 1st stage: 30 Nm
^ 2nd stage: 60 Nm
- Use fixed wrench to tighten:
^ 3rd stage: 90° (1/4) further turn
^ 4th stage: 90° (1/4) further turn

Note:
It is not necessary to retighten cylinder head bolts later after repairs have been performed.
Remaining installation in reverse order, note the following:

- Install camshaft timing chains.
- Install engine.
- Replace coolant.





Tightening torques