Installing Cylinder Head
Installing cylinder headTools
Information
Component overview
Tools and materials
Installing cylinder head
WARNING Danger of injury and crushing!
^ Risk of injury when lifting the cylinder head.
^ Wear suitable protective gear (e.g. gloves).
ATTENTION Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled)!
^ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing chain jumps over).
^ Proceed carefully while working as otherwise the engine can be damaged.
^ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
^ After working on the camshaft wheels, the timing must be set.
^ Please observe the general warning notes and working regulations
ATTENTION Leaks due to components being at too low a temperature or at different temperatures!
^ If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
^ Components must have reached at least 17°C throughout.
^ Components must not be too hot (distortion).
^ Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.
Note: If more extensive work was carried out, e.g. if the cylinder head was replaced, the exhaust manifolds, fuel injectors, fuel distributor pipe, combination valve, timing chain housing and various small parts must also be modified.
Note: Observe the most important working regulations and warning notes
Note: The cylinder-head gasket must be prepared for installation of the chain case lid. Seal the bores of the cylinder-head gasket in the area of the chain case lid using sealant.
Note: If more extensive work was carried out, e.g. if the cylinder head was replaced, the exhaust manifolds, fuel injectors, fuel distributor pipe, combination valve, timing chain housing and various small parts must also be modified.
ATTENTION Risk of damage to components as a result of incorrect cleaning methods!
^ Make sure not to score or scratch the sealing faces when cleaning.
^ When cleaning the sealing faces, make sure that no emery and sanding residues get into the coolant or into the combustion chambers.
^ Use sandpaper that is no coarser than less than 100!
^ Clean all coolant and engine oil off the threaded bores for the cylinder-head screws in the cylinder block. If water residues remain in the bores, hydraulic pressure could crack the cylinder block in this area when the cylinder-head screws are tightened.
Note:
^ It is best to use only a spatula and acetone to clean the sealing faces. Ensure good ventilation because of the acetone!
^ Use a cleaning cloth to wipe the sealing faces clean and remove any grease.
^ Replace the cylinder-head gasket.
^ Replace the cylinder-head screws with new ones.
1. Clean all sealing faces on the cylinder block and cylinder head. Make sure to remove all sealant residues and traces of oil. Ensure that the sealing faces are clean and free of grease.
2. Make sure that the dowel sleeves are inserted correctly in the cylinder block.
3. Clean all coolant and engine oil off the threaded bores for the cylinder-head screws in the cylinder block.
4. Position engine at the crankshaft at ignition TDC for cylinder 1. To do this, turn the crankshaft until the pulley is aligned with the TDC mark on the cylinder block -see Arrow-.
5. Position the cylinder head camshafts to ignition TDC of cylinder 1. This may involve turning the camshafts at the hexagon so that the camshaft guide T10068 fits into the two grooves on the camshafts -A-.
6. Fit seal. Check that the part number and lettering -2- can be read. The seal must be positioned correctly on both sleeves -1- of the cylinder block.
ATTENTION Risk of leaks and engine damage if cylinder-head gaskets are defective!
^ Avoid damaging the cylinder-head gasket (e.g. bends or pressure marks)! There is a danger of leaks.
^ Replace damaged cylinder-head gaskets.
7. Carefully fit the cylinder head with the help of an assistant. Make sure that the cylinder head is positioned flat on the cylinder-head gasket and is centered on the sleeves. Do not tilt the cylinder head.
8. Insert three rows of new cylinder-head screws. Longer screws are used in the middle row. Screw in the screws hand-tight.
9. Tighten the cylinder-head screws in three stages one after the other from the inside out according to the tightening sequence shown:
Note:
^ The cylinder-head screws do not need to be tightened.
^ The cylinder-head screws are arranged in three rows, with longer screws in the middle.
^ ^ Initial tightening: 30 (22 ft-lb.) Nm
^ ^ Final tightening: 50 (37 ft-lb.) Nm
^ ^ Torque angle: 2 x 90° (180°)
Subsequent work
1. Install timing chain.
2. Set the timing.
3. Fit chain case lid.
4. Install cylinder head cover.
5. Install intake-air distributor.
6. Fit wire harness around the cylinder head (see sub-section).
7. Suspend engine on mounting bracket (assembly support).
8. Install engine.