Installing Right Cylinder Head

INSTALLATION OF CYLINDER HEAD
- 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 with Hylomar SQ 32 M.




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




- 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.




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




- Fit guide rail to cylinder head.




- Align camshafts with open-end wrench.

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




- 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 2 441 / 445 / 446 / 442 locate firmly against cylinder heads.

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 45° before TDC position engine-wise until in TDC position.
- Hold crankshaft in TDC position with special tool 11 2 300.

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




- Fit sprocket with sensor pin (1) to intake camshaft on cylinder bank 1-4 with arrow in cylinder axis pointing upwards and long bores aligned centrally.
- Fit screws with no clearance.




- Fit special tool 11 2 400 to right cylinder head (cylinder bank 1-4).




- Install special tool 11 3 390 in special tool 11 2 400.
- 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:
- Three screws on left exhaust camshaft
- All screws on right exhaust camshaft,
- Three screws on left intake camshaft, all 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 2 444 / 443 / 442 / 446.




- Remove special tool 11 2 300.
- Turn over engine once.
- Tighten down remaining three screws in exhaust and intake camshafts on cylinder bank 5-8.
Tightening torque = 15 ± 2 Nm (11 ± 1.5 ft lb).




- Relieve load on special tool 11 3 390 and remove with special tool 11 2 400.
- 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.