Installing Left Cylinder Head

INSTALLATION
- Clean sealing faces of cylinder head and engine block, if necessary using wooden scraper to remove gasket debris.

CAUTION: Ensure that no gasket debris drops into the oil and coolant ducts. Threaded bores in engine block must be free of dirt and oil (danger of cracking).




- Coat contact surface between engine block and timing case cover with Hylomar SQ 32 M.




- Check that dowel sleeves are undamaged and correctly located.
- Fit new cylinder-head seal.





CAUTION: When fitting cylinder head, press oil separator outwards.




- Fit cylinder head and install new cylinder head screws.
- Do not wash off screw coating.

NOTE: Use special tool 00 9 120 as a torsion angle bracket.




NOTE: Tighten down cylinder head screws in sequence 1 ... 10.
Step 1 = 30 ±2 Nm
Step 2 = 80° ±5° Torque Angle
Step 3 = 80° ±5° Torque Angle




NOTE: Ensure that oil return pipe is correctly seated in oil separator.




NOTE:
- Check sealing ring in angle section and replace if necessary.
- Press oil separator into angle section.
- Tighten guide rail and retaining screw for oil separator.




NOTE:
- Fit guide rail to cylinder head.
- Tighten grub screw.
- Grub screw secures angle section in cylinder head: only replace with genuine spare part. Tightening torque 2-3 Nm (1.5 - 2.0 ft lb).




NOTE: Align camshafts with open-end wrench.

CAUTION: Do not damage the cylinder head. If necessary, rework open-end wrench.




CAUTION: Fit special tool 11 2 445 / 441 to camshafts on cylinder bank 1-4.





NOTE: In TDC position of first cylinder, marker bores of camshafts point upwards.




- Fit special tool 11 2 446 / 442 to camshafts on cylinder bank 5-8.





NOTE: In TDC position of first cylinder, marker bores of camshafts point upwards.




- Align all camshafts with open-end wrench in such a way that special tools 11 2 445 / 441 / 446 / 442 fit on cylinder heads with no gaps.

CAUTION: Do not damage the cylinder head. Machine open-end wrench accordingly if necessary.




- Fit special tool 11 2 443 to special tool 11 2 445 / 441 and secure with special tool 11 2 444 using the spark plug thread.




- Fit special tool 11 2 443 to special tool 11 2 446 / 442 and secure with special tool 11 2 444 using the spark plug thread.




- Rotate engine from before TDC position engine-wise until in TDC position.
- Secure crankshaft in TDC position with special tool 11 2 300.

CAUTION: Remove special tool 11 2 300 before starting engine.




- Fit sprocket and chain to intake camshaft on cylinder bank 5-8 in such a way that arrow on cylinder axis faces upwards and long bores are centrally aligned.
- Fit screws with no clearance.




- Install special tool 11 3 390 in right timing case cover.




- Tighten tensioning rail by turning the adjusting screw on the special tool 11 3 390 with special tool 00 9 250 to 1.3 Nm.

NOTE: If installation tolerance is unfavorable, attach special tool 00 9 250 from underside.

Tighten sprockets in following order:
- All screws on left exhaust camshaft.
- Three screws on right exhaust camshaft, all screws on left intake camshaft
- Three screws on right intake camshaft.
Tightening torque = 15 ± 2 Nm (11 ± 1.5 ft lb).




- Remove special tools 11 2 444 / 443 / 441 / 445.




- Remove special tools 11 2 44 / 443 / 442 / 446.




- Remove special tool 11 2 300.
- Turn over engine once.
- Tighten remaining three screws on right exhaust camshaft and remaining three screws on right intake camshaft.
Tightening torque = 15 ± 2 Nm (11 ± 1.5 ft lb).




- Loosen special tool 11 3 390 and remove.
- Assemble engine.

- Reinstall all auxiliary components in reverse order of disassembly, paying close attention to installation notes and torque specs.
- Adjust engine idle speed and check CO level.