Cylinder Head, Installing

Cylinder head, installing

Note:
^ Always replace cylinder head bolts when assembling.
^ Replace self-locking nuts.
^ Always replace bolts that are tightened to a specified angle.
^ If repairing, carefully remove any remains of gasket material from the cylinder head and cylinder block. Make sure that no long scores or scratches are made on the surfaces.
^ Carefully remove any remaining emery and abrasive material.
^ Remove new cylinder head gasket from packaging, just before installation.
^ Handle gasket extremely carefully. Damaging the silicone coating or the indented area will lead to leaks.
^ No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.
^ Ensure fuel hoses are tight.





- Before positioning cylinder head, set crankshaft and camshaft to TDC of No. 1 cylinder.





- Remove bolts -1- and -2- on turbocharger bracket (about 2 full turns each) to avoid stressing when installing the cylinder head.
- Place cylinder head gasket in position.

^ Note position of centralizing pins in cylinder block (arrows).
^ Check installation position of cylinder head gasket. The Part No. should be legible from intake side.

- Place cylinder head in position.
- Insert cylinder head bolts and tighten by hand.





- Tighten cylinder head bolts in two stages in sequence shown as follows:
- Stage 1: 40 Nm
- Stage 2: Torque a further 180 degrees (1/2 turn) with a rigid wrench.
- It is permissible to torque by 2 x 90 degrees

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





- Install turbocharger with new gasket and bolt bracket to cylinder block.
- Install toothed belt (adjust valve timing).

Note:
Follow all instructions for removing and installing toothed belt.

- Install cylinder head cover.
- Install ribbed belt and tensioning element.
- After connecting battery terminals, enter anti-theft code for radio
- Close electric windows in front doors all the way to their top positions using electric switches.
- Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
- Set clock to correct time.
- Perform adaption of throttle valve control module:
- Interrogate DTC memory:

Note:
DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.

- Electrical connections and routing