Cylinder Head, Installing

Cylinder head, installing

Special tools:
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

Note! As 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.

Note! For tightening torques not in the text, see Tightening torque 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 center (TDC).
Continue turning counter-clockwise until the piston in cylinder 1 is approximately 2-3 cm before top dead center (BTDC).
Install the crankshaft stop999 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. See Tightening torque Tightening Torque.

Installing valve lifters and camshafts
See 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 completely covered without any excess. Use roller 951 2767 Roller 951 2767 Roller

Note! Ensure that no liquid gasket gets in to the oil ducts.

Installing the camshaft covers




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

Cleaning
To clean the camshaft journal and mating surface, use emery cloth P/N 951 1024.

Note! When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Installing the front camshaft seal





Use drift 999 5718 Drift 999 5718 Drift.
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.
Continue the work with the next sealing ring.

Note! If there are grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.

Securing the camshafts




Use camshaft adjustment 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.