Cylinder Head Assembly Overview

Cylinder Head Assembly Overview





1 Cylinder Head

• See notes: --> [ Only remove the plastic protectors installed to protect the open valves immediately before positioning the cylinder head. ] Cylinder Head Cover

• Check for distortion.

• Removing and installing, refer to --> [ Cylinder Head ] Cylinder Head.

• All of the coolant must be replaced after installation.

• Checking compression, refer to --> [ Compression, Checking ] Testing and Inspection.

2 Washer

• For cylinder head bolt

3 Cylinder Head Bolt

• Observe sequence for loosening and tightening. Refer to --> [ Cylinder Head ] Cylinder Head.

• Before installing, insert shims --> [ 2 Washer ] into cylinder head.

4 25 Nm

5 Lifting Eye

6 Gasket

• Replace

7 Vacuum Pump

CAUTION!
Do not disassemble the vacuum pump under any circumstances because it can cause the vacuum part to malfunction. The result would be brake booster failure.

• Removing and installing, refer to --> [ Vacuum Pump ] Service and Repair.

8 10 Nm

9 Coolant Connection

• Coolant hose connection diagram, refer to --> [ Coolant Hose Connection Diagram ] [1][2]Cooling System.

10 10 Nm

11 Seal

• Replace

12 25 Nm

13 Lifting eye

14 Cylinder Head Gasket

• Replace

• Observe identification. Refer to --> [ Cylinder Head Seal Identification ]

• All of the coolant must be replaced after removing and installing.

15 Camshaft Position Sensor (G40)

• For camshaft position

16 10 Nm

Checking Cylinder Head for Distortion





Special tools, testers and auxiliary items required

• Straight edge 500 mm (VAS 6075)

• Feeler gauge

Procedure

- Check the cylinder head for distortion with the straight edge and feeler gauge in several places.

• Maximum permissible distortion: 10 mm

• Remanufacturing diesel cylinder heads is not permitted.

Cylinder Head Seal Identification





• Replacement part No. = - arrow 1 -

• Control code = - arrow 2 - (ignore this!)

• Holes = - arrow 3 -

• Installation position: the identification faces upward.

• Depending on piston projection, varying cylinder head gasket thicknesses can be installed. When replacing the seal, install a new seal with the same identification - arrow 3 -.

• When installing new pistons or working with a partial motor, check the piston position at TDC. Refer to --> [ Piston Projection in TDC, Checking ] Testing and Inspection.