Installing the Cylinder Head

Installing the cylinder head

Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
951 2767 Roller 951 2767 Roller
999 5450 PUNCH 999 5450 Punch
999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
999 5454 PRESS TOOL 999 5454 Press Tool
999 5718 Drift 999 5718 Drift
999 5719 Drift 999 5719 Drift

Note! Since the illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Tightening torque

For tightening torques not in the text, see Tightening torque, B5234T9 Tightening Torque.

Aligning the crankshaft





Turn the crankshaft counter-clockwise (viewed from the rear of the engine) until the piston in cylinder 1 reaches top dead centre (TDC).
Continue turning counter-clockwise until the piston in cylinder 1 is approximately 2-3 cm before top dead centre (BTDC).
Install the crankshaft stop 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool. Ensure that it bottoms out against the cylinder block.
Now turn the crankshaft clockwise (viewed from the rear of the engine) until the crankshaft counter-weight is in contact with the crankshaft stop.

Installing the cylinder head





Install a new cylinder head gasket .
Install the cylinder head.
Use new screws .
Lubricate and install all the screws.
Tighten the screws in the following order. Tighten the screws alternately from the centre and outwards.
1. 20 Nm
2. 60 Nm
3. Angle-tighten 130° . Use protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.


Note! If the valves have been replaced, the valve clearance must be adjusted. Refer to: Valve clearance, B5234T9, B5244T7 Valve Clearance Valve clearance Valve Clearance

Installing tappets and camshafts

See Valve clearance, B5234T9, B5244T7 Valve Clearance Valve clearance Valve Clearance.

Applying liquid gasket





Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
Install new O-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 11 61 059 to the camshaft cover. The surface must be fully covered without any excess. Use roller 951 2767 Roller 951 2767 Roller

Note! Make sure that no liquid gasket gets in to the oil channels.

Installing the camshaft covers





Lubricate the camshaft lobes, the camshaft bearing surfaces and the tappets.
Install the camshaft cover.
Install 2 press tools 999 5454 PRESS TOOL 999 5454 Press Tool.
Pull the camshaft cover alternately down, keeping it parallel to the cylinder head with the press tools
Install all the screws and tighten.
Remove the press tools.
Install the spark plugs. Tighten to 30 Nm .
Install the control valve for the variable valve timing unit with a new gasket. Tighten.

Installing the front camshaft seal





Use drift 999 5718 Drift 999 5718 Drift on camshafts with VVT units. Use drift 999 5719 Drift 999 5719 Drift on camshafts without VVT.
Use new seals. Lubricate the surface of the seal that the camshaft rotates against.
Tap in the seal until the drift bottoms against the end of the camshaft.

Installing the rear camshaft seal





Use drift 999 5450 PUNCH 999 5450 Punch.
Lubricate the surface of the seal that the camshaft rotates against.
Install the seal.
Press in the seal until the drift bottoms out.

Note! If there are wear grooves on the camshaft, the seal can be pressed in another 2 mm by reversing the tool's sleeve.

Securing the camshafts





Use camshaft tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.

Note! The camshafts must not be turned more than is listed in the text below. The valves may be damaged!

Screw the adjustment tool sections together into one.
Check that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.