Install

REINSTALL CYLINDER HEAD
- Install in reverse order of removal paying closing attention to installation notes from the cylinder head removal section. Remove.

NOTE: When installing a new cylinder head, install new washers without locking them. Make sure that no washers are missing. When installing the cylinder head, conform with the waiting time for hydraulic valve tappets. Service Precautions




- Clean mating surfaces on cylinder head and crankcase, if necessary removing remainders of gaskets with gasket remover** and a hard wood scraper. Make sure that remainders of gaskets do not fall into oil and coolant bores.
- Install new cylinder head gasket.
- Check dowel sleeves (1) for damage and correct installed position.




NOTE: Gaskets which are 0.3 mm thicker are available for machined (ground) cylinder heads.

- Identification: 2.5 for 2.5 liter. + 0.3 for 0.3 mm (0.012 in) thicker gasket for repair machined cylinder head.




NOTE: Mount cylinder head and tighten new bolts (lightly oiled) in sequence of 1 ... 14 in three steps.
Step 1: Tightening torque 30 ± 2 Nm (22 lb ft)
Step 2: Torque angle 90 ± 3°
Step 3: Torque angle 90 ± 3°

CAUTION: Cylinder head bolts may only be used once. Keep oil out of tapped bores in the engine block (danger of cracking the block, wrong tightening torque values).




NOTE: Use torque angle tester together with Special Tools 11 2 250 and 11 2 113.

Camshaft Adjusting Procedures
- Hold crankshaft in TDC position with Special Tool 11 2 300.

CAUTION: Remove special tool before operating the engine.

CAUTION: If it is necessary to correct the camshaft adjustment to such an extent that there is valve movement in cylinders 1 and 6, first turn the crankshaft about 30° away from TDC position in the engine's direction of rotation and return to TDC only after turning the camshaft. This prevents contact between the valves and pistons.




- Turn camshafts until the cam peaks of intake and exhaust cams for cylinder no. 1 face each other.
- Unscrew the three rear studs for the valve cover.




- Camshaft may be turned on the hexagon with a 24 mm wrench.
- Hold camshaft with Special Tool 11 3 240.

CAUTION: Be careful that the bearing plate is not damaged. Machine the fork wrench to size accordingly if necessary.




- Install primary timing chain on the sprocket and center with the exhaust camshaft. Arrow on sprocket faces up. Mount sprocket that the tapped bores are to the left of the slots as the sprocket will be moved to the left when installing the chain tensioner.




- Install pulse sender on the intake camshaft if applicable.




- Mount both sprockets complete with chain. Arrows on sprockets face up.




- Install bolts to be turnable without play, but do not tighten at this stage.




- Screw in and tighten chain tensioner sleeve. Insert chain tensioner piston (1) that the guides engage in the tensioning rail. Install spring (2) and bolt (3).

NOTE: Replace seal. Torque to 50 Nm (37 ft lb).




- Unlock chain tensioner arrest.
- Remove Special Tool 11 3 290.




- Tighten both sprockets, beginning at the intake side, with an initial torque of approx. 5 Nm and afterwards in a second step to the specified final torque of 22 Nm (16 lb ft).

NOTE: Remove Special Tools 11 2 300 and 11 3 240. Crank engine at least twice in direction of rotation. Check camshaft adjustment.

- Reassemble covers, manifolds and auxiliary components in reverse order of disassembly, paying close attention to installation notes and tightening torques.