Installing
Installing cylinder headATTENTION: Damage due to ingress of dirt
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Fitting cylinder head side 1 - 3:
1. Turn the crankcase at the assembly support in such a way that side 1-3 stands vertically upwards.
2. Fit new cylinder-head gasket. The inscription 'OBEN/TOP' must be clearly visible.
3. Carefully position the cylinder head on the crankcase. Pay attention to the dowel sleeves.
4. Screw in 12 M1 0 Torx screws evenly and tighten according to the prescribed tightening sequence -1 -12-. Initial tightening 22 ft. lbs., loosen all screws in reverse tightening sequence; Initial tightening 15 ft. lbs.; Final tightening, 2 x torque angle 70°
5. Screw in and tighten four Torx screws with M6 x 30 captive washers (10.9) -1 -4- at the chain slot. Use of a magnetic bit is recommended so that the screw to be fitted in the slot -item 4cannot fall into the crankcase. Tightening torque 9.5 ft. lbs.
6. Fit threaded bolt for guide rail -1 - with a new O-ring at the cylinder head. Tightening torque 7.5 ft. lbs..
The installation of cylinder head side 4 -6 is carried out in the same way as the assembly sequence for side 1-3 with the following change:
^ The threaded bolt for guide rail 4-6 on the cylinder head (belt pulley side) -1- is inserted only after the timing chain has been fitted on the camshaft timing gears.
Subsequent work for installing cylinder head
1. Insert three new O-rings at the spark-plug recesses -arrows-, lightly coat with high-pressure grease.
Note: There must be no visible signs of wear on the flat-base tappets and fitting bores of the flat-base tappet housing.
2. Fit flat-base tappet housing with 11 M6 x 35 Torx screws -1 - and tighten screws from the inside out. Tightening torque 7.5 ft. lbs..
ATTENTION: Interchanged or dirty flat-base tappets.
^ Damage to engine components
^ The components have been run in the fitting bores in the housing, therefore do not interchange them.
^ Pay attention to cleanliness.
3. Coat the flat-base tappets with new engine oil and insert them in their original position into the fitting bores in the flat-base tappet housing. The operating plunger position (inlet side) is preset by the dowel pin -arrow-.
4. Install camshaft and set timing.
5. Install cylinder head cover.
6. Fit exhaust manifold with new screws M8 x 26. Position new metal seal with the seam towards the cylinder head. Tighten screws from the inside out. Tightening torque 17 ft. lbs.