Cylinder Head, Installing

Cylinder head, installing

Note:
^ Replace cylinder head bolts.
^ Replace self-locking nuts and bolts during assembly work.
^ Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.
^ In case of repairs, carefully remove sealant residue from cylinder head and cylinder block. Avoid introducing any scratches or scoring.
^ Thoroughly remove all sanding and grinding residue.
^ Pocket holes in cylinder block for cylinder head bolts must be free of oil and coolant.
^ Do not remove new cylinder head gasket from package until immediately before installing.
^ Handle gasket with extra care. Damage in silicon layer and recessed area lead to leakage.
^ Install cylinder head gasket onto guide sleeves. Marking oben (top) or part number must face toward cylinder head.
^ Secure all hose connections using hose clamps appropriate for the model type:

Installation is reverse of removal, noting the following:
- Before installing cylinder head, set crankshaft and camshafts to TDC cylinder 3:





- T40030 camshaft adjuster gauge must be inserted at both cylinder heads...





- ... and T40026 locking pin must be threaded in.





- Install cylinder head gasket.
^ Observe centering pins (arrows) in cylinder block.
^ Pay attention to installed position of cylinder head gasket, marking oben (top) or part number must face toward cylinder head.
- Install cylinder head.
- Insert new cylinder head bolts and hand-tighten.





- Tighten cylinder head bolts in sequence, in two stages.
- Tighten using torque wrench:
^ 1. Stage: 40 Nm
- Tighten using a solid wrench:
^ 2. Stage: 180° (1/2 turn) further

Note:
^ Two additional turns of 90° are permissible.
^ It is not necessary to re-tighten the cylinder head bolts.

- Install toothed belt (adjust timing).

Note: After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

- Install left front exhaust pipe with catalytic converter.
- Install right front exhaust pipe with catalytic converter.
- Install exhaust system free of stress.
- Install centering pin for intake manifold.
- Install intake manifold.

See Caution for connecting Telematics battery
- Observe safety precautions after connecting the battery.
- Replace coolant.
- Fill up power steering fluid and bleed steering system:

Tightening torques