Cylinder Head, Installation

- Standard Handle tool No. 999 1801, or equivalent
- Drift tool No. 999 5449, or equivalent
- Locating Tool No. 999 5451, or equivalent
- Locating Tool No. 999 5452, or equivalent
- Retainer tool No. 999 5453, or equivalent
- Press Tool No. 999 5454, or equivalent
- Retainer tool No. 999 5508, or equivalent

Universal Tools:
- Short Haired Roller tool No. 951 1205, or equivalent

NOTE: For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Reconditioning". Tools and Equipment

Procedure





1. Lock crankshaft in position:
- Use crankshaft locking tool No. 999 5451, or equivalent at rear of engine.
- Turn crankshaft counter-clockwise until counterweight meets stop.
- Check that piston in last cylinder is between TDC and BDC.





2. Install tappets:
- Tappets must be oiled and replaced in original order.

NOTE: If tappets have leaked oil, it is best to top them up using an oil can via the hole in the side.





3. Install lower section of cylinder head:
- Install new cylinder head gasket.
- Max. length 12 mm screw: 158 mm
- Oil screws.
- Tighten screws in three stages as follows (start from the middle and work out):
Stage 1. 20 Nm (15 ft lb)
Stage 2. 60 Nm (45 ft lb)
Stage 3. 130° (protractor tightening)
- Insert new O rings round the spark plug wells.





4. Apply liquid gasket compound:
- Apply liquid gasket compound part No. 1 161 059-9, or equivalent to camshaft carrier, using short-haired roller tool No. 951 1205, or equivalent.

NOTE: Make sure no liquid gasket gets into coolant or oil passages.





5. Install camshafts
- Install camshafts.
- Lock camshaft front ends using locking tool No. 999 5453 and rear ends with tool No. 999 5452, or equivalents, (without extension pieces).
- Camshaft markings: E = exhaust, I = intake.
They are also marked with the part number.





6. Install cylinder head top section:
- Put top section in position.
- Tighten it against cylinder head using press tools No. 999 5454, or equivalent (2 tool required).
- Tighten top section from center outwards to 17 Nm (13 ft lb).
- Remove locking tool No. 999 5453 or 999 5508 and press tool 999 5454, or equivalent.

NOTE: There are different versions with and without holes for the air pump and crankcase ventilation.





7. Install camshaft front seals
- Use drift tool No. 999 5449 and standard shaft tool No. 999 1801, or equivalent.
- Grease seals.
- Tap seals home.