Cylinder Head Assembly: Service and Repair

Cylinder Head, Assembly





WARNING: DO NOT re-use any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time This includes but is not limited to, nuts bolts, washers. self-locking nuts or bolts, circlips, cotter pins. For replacements always use new parts.

CAUTION:
- Part numbers are for reference only. Always check with your Parts Department for latest information,
- Coolant/antifreeze MUST NOT be reused when replacing engine, cylinder head, cylinder head gasket, radiator and heater core.

NOTE: When replacing cylinder head, lubricate hydraulic valve and camshaft contact surface.

1 - Ignition cable guide
2 - Cap
3 - Cylinder head cover
4 - Cylinder head cover gasket
- always replace
- note installation position
5 - 0-ring
always replace
6 - Exhaust manifold
- comes in 2 parts
- with CO take-oil pipe attached
7 - Nut, 25 Nm (18 ft lb)
8 - Exhaust manifold gasket
- two-piece
- always replace
- note installation position
9 - Chain tensioner for double drive chain
2O Nm (15 ft lb)
10 - Bolt, 10 Nm (7 ft lb)
11 - Ignition distributor with rotor arm
12 - 0-ring
- always replace
13 - Bolt, 10 Nm (7 ft lb)
14 - Retaining plate
15 - Camshaft cover
- coat sealing surfaces with AMV 188 001 02
- reseal cylinder head gasket refer to "Camshaft, Engine - Removing/Installing". Service and Repair
16 - Cylinder head gasket
- always replace
- note installation position
- marking TOP must face cylinder head
17 - Cylinder head
- checking for distortion, Testing and Inspection
- installing, see "Cylinder Head, Installing" below
18 - Cylinder head bolt
- always replace
- note torque and tightening sequence, see "Cylinder Head, Installing" below
19 - Lower intake manifold gasket
always replace
20 - Upper intake manifold gasket
always replace
21 - Fuel rail - 10 Nm (7 ft lb)
22 - Lower intake manifold
23 - Tensioner for poly-ribbed belt
24 - Intake manifold support
25 - Bolt, 25 Nm (18 ft lb)
26 - Upper intake manifold
installing, first install and tighten lower intake
manifold 22, then intake manifold support 24
27 - Trim cover
28 - Bolt, 25 Nm (18 ft lb)
29 - Flame trap coil
30 - Circlip
31 - Nut, 10 Nm (7 ft lb)

Cylinder Head, Installing




- install cylinder head gasket
- note installation position, check centering dowels at holes 12 and 20
- install cylinder head
- fit all cylinder head bolts
- hand tighten only
- always replace

Tightening Torque, Engine Cold
Tighten bolts in sequence:
Stage I = 40 Nm (29 ft lb)
Stage II = 60 Nm (43 ft lb)

- tighten in sequence additional 1/2 (180°) turn further in one movement or two additional 1/4 (90°) turns are permissible
- reverse sequence to remove bolts

NOTE: It is not necessary to re-tighten cylinder head bolts during scheduled maintenance or after performing repairs.