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! 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, B5254T7 Tightening Torque.

Preparatory work

Aligning the crankshaft




Turn the crankshaft counter-clockwise (seen from the engine's trailing edge) until the piston in cylinder 1 reaches top dead center (TDC).
Continue turning counter-clockwise so that the piston in cylinder 1 is approx. 2-3 cm below top dead center (TDC). Install: 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool Make sure that it stops against the engine block.
Turn the crankshaft clockwise (seen from the engine's trailing edge) until the crankshaft's counterweight has contact up against the crankshaft stop.

Installation

Installing the cylinder head




Install a new cylinder head gasket.
Install the cylinder head.
Use new screws.
Lube all screws with oil and install them.
Tighten, see: Tightening torque, B5254T7 Tightening Torque.

Installing tappets and camshafts
See: Valve clearance, B5254T7 Adjustments.

Applying liquid gasket




Wipe the sealing surfaces on the camshaft cover and cylinder head clean from oil film.
Install new O-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 11 61 059 on the camshaft cover. The surface shall be completely covered without any excess. Use: 951 2767 Roller 951 2767 Roller

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

Installing the camshaft covers




Lubricate the camshaft lobes, the camshafts' bearing surfaces and the valve depressors.
Install the camshaft cover.
Install: 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. Tighten the screws from the middle and outwards.
Remove 999 5454 PRESS TOOL 999 5454 Press Tool.





Securing the camshafts




Install: 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the camshafts' trailing edge.

Note! The camshafts may not be turned more than what is necessary to install the gauges. The valves may be damaged.

Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Installing the front camshaft seal




Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal.
For camshafts with variable valve timing:
Use: 999 5718 Drift 999 5718 Drift. Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out.
For camshafts without variable valve timing:
Use: 999 5719 Drift 999 5719 Drift. Use the screws for the timing belt wheels to pull in the drift until it bottoms out.

Installing VVT-units




Press the timing belt pulley into place with the VVT-units on the camshafts. Set the VVT-units according to the marking.

Install:
- the center screws that hold the VVT-units to the camshafts. Do not tighten.
- the upper timing belt cover.

Note! Remove the belt.