Cylinder Head/Gasket, Installing
Cylinder head/gasket, installingSpecial tools: 951 2955 951 2957 999 7103, 999 5718, 999 5719, 999 5451, 999 5452, 999 5433, 999 7107
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.
Note: For tightening torques, see Specifications.
Note: To ensure that there is no exhaust leakage, see: Flanged joint, assembling.
Cleaning
Cleaning the gasket faces
Caution: Use a fume bonnet or extractor when using gasket solvent
Note: Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.
Blow the oil ducts clean.
Clean the gasket faces for:
- manifold. Check that the stud bolts are tightened and undamaged
- the intake manifold
- the engine block - the camshaft cover.
Installing
Removing the starter motor
Lift out the coolant hose from the bracket. Loosen the nuts on the bracket for the coolant hose and move the bracket to one side so that you can access the screws to the starter motor. Loosen the flat pin connector and the positive cable from the starter motor. Loosen the screws holding the starter motor on the gearbox and lift out the starter motor.
Aligning the crankshaft
Remove the cover plug. Turn the crankshaft a little clockwise. Fit the crankshaft stop. Use: 999 5451. Ensure it bottoms against the engine block. Turn the crankshaft anti-clockwise until it stops against the crankshaft stop. Check that the marking on the crankshaft's pulley corresponds with the marking on the oil pump.
Installing the cylinder head
Fit a new cylinder head gasket. Fit the cylinder head. Check that no cables or hoses are caught between the cylinder head and the engine block. Use new bolts, lubricate and fit all screws. Tighten the screws in sequence as illustrated and to the torque. Tighten according to Specifications. Specifications
Installing valve lifters and camshafts
Note: When fitting a new cylinder head or new camshafts, the valve clearance should be set according to: Valve clearance, setting/adjusting.
Note: Note: Make sure that the lifters are in the same position as before.
Lubricate the valve tappet wells. Fit all valve lifters. Lubricate the camshaft's bearing seatings. Position the intake camshaft. Make sure that the groove at the rear edge of the camshaft lies above an imaginary centre line. Position the exhaust camshaft. Make sure that the groove at the rear edge of the camshaft lies above an imaginary centre line.
Applying liquid gasket
Caution: Ensure that no liquid gasket gets into the oil ducts.
Wipe the film of oil from the contact faces on the camshaft cover and cylinder head. Fit new O-rings around the spark plug wells by the cylinder head. Apply liquid gasket 116 1059 on the camshaft cover. Use roller 951 2767. The surfaces must be completely covered without any surplus.
Installing the camshaft covers
Lubricate the camshaft cams, the camshaft's bearing surfaces and the top of the valve lifters. Fit the camshaft cover. Position the press tool. Use: 999 5454. Crosswise tighten the camshaft cover parallel to the cylinder head with the press tool. Fit all the screws and tighten from the middle out to the edges. Tighten according to: Tightening torque. Remove the press tool.
Fit the front engine bracket
Install:
- the front engine bracket
- the screws to the front engine bracket at the front edge of the cylinder head, 3, and on the intake side, 2. Tighten according to: Tightening torque
- the screw to the inner belt protection cover on the cylinder head.
Fitting the lifting brace
Fit the lifting brace. Use: 999 7103 and tighten the tool. Remove tool: 999 7107 Fit the bracket for the servo pipe.
Fitting of 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. Use the variable valve timing unit's mounting screw. Tighten until the mandrel bottoms. For camshafts without variable valve timing:
Use: 999 5719. Use the screws to the cam pulley to draw in the mandrel until it bottoms.
Installing the camshaft adjustment tool
Use: 999 5452.
Install:
- the gauge belonging to the exhaust camshaft (drilled hole).
- the gauge belonging to the intake camshaft (threaded hole). Screw together the gauges into a single unit.
Fitting the variable valve timing unit on the intake camshaft
Push on the pulley with the variable valve timing unit on the camshaft.
Install:
- the centre screw holding the variable valve timing unit on the camshaft and do not tighten.
- upper cam pulley cover. Position the variable valve timing unit according to the marking.
Fitting the pulley on the exhaust camshaft
Install:
- pulley on the exhaust camshaft according to the marking.
- the 3 screws. Do not tighten.
Position the camshaft pulley according to the marking on the upper cam belt cover and remove the upper cam belt cover.
Installing timing belt
Caution: Ensure that the camshaft gear is still positioned according to the marking on the upper cam pulley. If not, repeat the exercise until the markings match.
Tighten the centre screw on the cam belt tensioner with 5 Nm in the 10 o'clock position.
Install the belt in the following order:
- the crankshaft
- the idler pulley
- intake camshaft gear
- exhaust camshaft gear
- water pump
- tensioner pulley.
Tensioning of cam belt
This setting is done on a cold engine. A suitable temperature is about 20 ° C/68 ° F. At higher temperatures, for example with a warm engine or high ambient temperatures, the needle takes a position further to the right. The needle's position when setting the belt tensioner at different engine temperatures is evident from the figure. Keep the centre screw locked and turn the eccentric on the belt tensioner clockwise until the indicator on the tensioner passes the marking and reaches the end position and tightens the screw. Tighten the centre screw holding the variable valve timing unit and the screws to the exhaust cam belt pulley. Tighten according to: Tightening torque. Ensure that none of the screws have bottomed. Fit the plugs on the variable valve timing unit. Tighten according to: Tightening torque.
Adjusting the belt tension
Loosen the screw on the camshaft belt tensioner and turn the eccentric back so that the indicator reaches the marked position in the centre of the window. Ensure all centre screws are kept locked. Hold the eccentric locked and tighten the centre screw. Tighten according to: Tightening torque Check that the indicator is in the right position.
Removing the gauges
Remove:
- camshaft gauges. Use: 999 5452 from the rear edge of the camshafts
- the crankshaft stop. Use: 999 5451. Fit the plugs with a new sealing washer. Tighten according to: Tightening torque -
Checking the markings and belt tension
Press on the toothed belt to check that the indicator on the tensioner moves easily. Position the upper transmission cover. Turn the crankshaft 2 turns and check that the markings on the crankcase and camshaft gear correspond. Check that the indicator on the belt tensioner lies within the marked position. Adjust if necessary. Remove the upper transmission cover.
Installing parts
Fit the oscillation damper. Tighten the centre nut. Tighten according to: Tightening torque. Use counterhold: 999 5433. Remove the counterhold and fit new screws. Tighten according to: Tightening torque.
Installing parts
Install:
- the feed line to the servo pump and remove the seals
- front/lower belt protection cover and tighten the screw
- the outer auxiliary unit belt. Wind up the tensioner. Use: 999 7109. Fit the belt.
- the wing liner
- the front wheel
Fitting of exhaust manifold
Install:
- new seal, ensure the surfaces are clean. Lift up the exhaust manifold
- new nuts. Tighten as shown: Tightening torque
- the heat shield plate.
Installing catalytic converter
Install:
- new seal by the partition between the catalytic converter and the exhaust system, ensure the surfaces are clean
- new nuts and tighten. Hang the catalytic converter on the rubber suspensions
- The SIPS member.
Installing parts on the rear edge of the engine
Install:
- rotor, tighten the screw
- cover
- bleeder hose at the rear edge of the cylinder head.
- screws, 2, to the lifting eye at the rear of the cylinder head and tighten. Hook the EVAP valve on the lifting eye. Connect the connector to the lambda sonds.
Installing the intake manifold and gasket
Note: Ensure that the gasket faces are clean.
Install:
- new gasket. This is held in place by the lower screws for the intake manifold
- the intake manifold
- Note: Route the crankcase ventilation hose up between cylinders 2 and 3.
hose between the oil trap and the intake manifold
- screws for the top row. Tighten according to: Tightening torque.
Installing the fuel rail
Lubricate the O-rings on the injection valves using lubricant 116 1580. Push down the distribution pipe and ensure all injectors are positioned correctly. Push together the quick coupling until a click is heard. Secure the distribution pipe as well as the clamps on the fuel pressure pipe. Connect all connectors to the injectors and to the fuel pressure sensor.
Fit a new clamp on the crankcase ventilation hose and secure
Installing the ignition coils
Install:
- the ignition coils according to the marking made during dismantling
- earth points, 2
- cable conduit at the rear edge of the cylinder head.
Connect the connectors to:
- the variable valve timing (VVT) solenoid
- the camshaft position sensor
Installing parts
Install:
- the upper belt protection cover and tighten the screws
- the front/upper belt protection cover by pushing it into position on the upper one.
Fit the front engine bracket
Install:
- the engine bracket
- the screws (2) to the engine bracket on the cylinder head
- movement limiter
- the screws (1) to the movement limiter for the engine bracket on the right-hand frame side member. Tighten according to: Tightening torque.
Remove the lifting brace 999 7103
Push on the expansion vessel and secure the hoses.
Fitting the upper intake manifold
Caution: Ensure that the guides for the lower section are in the correct position.
Install:
- new gaskets to the top section of the intake manifold
- the upper intake manifold and tighten the screws crosswise. Tighten the screws on the intake manifold. Tighten according to: Tightening torque the canister hose
- the canister hose
- brake vacuum hose.
Connect the connector to:
- the pressure sensor on the intake manifold. Fit a new cable tie on the cable harness
- the mass air flow sensor.
Finishing
Installing air filter module
Fit the air filter module according to: Air cleaner (ACL) module, replacing
Checks
Top up with coolant. Use filling equipment: 951 2957 and cover: 951 2955 Start the engine and check for any leakage as well as the function of the engine.