Cylinder Head, Installing
Cylinder Head, Installing
Procedure
• Tightening specifications, refer to => [ Cylinder Head Overview ] Cylinder Head Overview and => [ Cylinder Head, Tightening Specifications and Sequence ] Cylinder Head Overview.
The sealing surfaces could be damaged.
• Carefully remove sealant residue from cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging cylinder block.
• No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.
Risk of leaks in cylinder head seal.
• Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves.
• If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.
Risk of damaging valves and piston heads after working on valve train.
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace bolts which have been tightened to an additional torque.
• Replace seals, gaskets and O-rings.
• If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover.
• Secure all hose connections with hose clamps appropriate for the model, refer to the electronic parts catalog ETKA.
• It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.
- Check whether camshafts of both cylinder heads stand in "TDC" position.
• Camshaft clamp (T40070) mounted on both cylinder heads and tightened to 25 Nm - arrows -.
• TDC locking pin (T40227) installed.
• The following illustrations show the left cylinder bank 2 instead.
- If there are no alignment bushings - arrows - at the locations marked in the cylinder block, insert them.
- Install the cylinder head gasket on the alignment bushings in the cylinder block.
• Cylinder head seal installation position: Identification "oben" (top) or the cylinder head part number.
- Set cylinder head in place.
- Install the cylinder bolts all the way in by hand.
- Tighten the cylinder head bolts. Refer to => [ Cylinder Head, Tightening Specifications and Sequence ] Cylinder Head Overview.
• There is no requirement to tighten the cylinder head bolts after repairs.
- Tighten the locking bolt - arrow -.
- Check if the guide rail for the camshaft timing chain tensioner is secured with the locking pin (T40071).
• If the tensioning element was removed from the chain tensioner, then the installation position must be noted: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail.
• Ignore - arrow -.
- Clean the chain tensioner oil strainer - 2 -.
- Position a new seal - 3 - on the rear of the chain tensioner - 1 -.
- Insert the chain tensioner and position the camshaft timing chain as shown in the illustration.
- Fasten bolts - 1 - and - 2 -.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair
- Install the high pressure line and the intake manifold.
- Position the camshaft timing chain on the camshafts => [ Installing ] Camshaft Timing Chains, Removing from Camshafts.
- Install the timing chain covers. Refer to => [ Left Timing Chain Cover ] Left Timing Chain Cover or => [ Right Timing Chain Cover ] Right Timing Chain Cover.
- Change engine oil. Refer to Maintenance Procedures.
- Replace coolant => [ Filling ] Procedures.