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 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 Specifications. Tightening Torque

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.

Installing the cylinder head




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

Installing valve lifters and camshafts
See: Valve clearance Adjustments

Applying liquid gasket

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




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.
Brush on liquid gasket, part number 11 61 059, on the camshaft cover. The surface shall be completely covered without any excess. Use: 951 2767 Roller 951 2767 Roller.

Installing the camshaft covers




Lubricate the camshaft lobes, the camshafts' bearing surfaces and the valve depressors.
Install the O-ring.
Install the camshaft cover.
Install: 999 5454 PRESS TOOL 999 5454 Press Tool
Tighten down the camshaft cover parallel with the cylinder head using: 999 5454 PRESS TOOL 999 5454 Press Tool
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 gauge to the camshafts as well as the screw holding the gauges 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 camshaft with VVT, use: 999 5718 Drift 999 5718 Drift. Use the VVT-unit's attaching screw. Tighten until the drift stops.
For camshaft without VVT, use: 999 5719 Drift 999 5719 Drift. Use the screws for the timing belt's pulley to tighten the drift until it stops.

Installing the variable valve timing (VVT) unit on the intake camshaft




Press the timing gear pulley and variable valve timing (VVT) unit on to the camshaft. Set the variable valve time (VVT) unit according to the marking.

Install:
- the center screw that holds the VVT-unit to the camshaft. Do not tighten.
- the upper timing belt cover.

Installing the timing gear pulley on the exhaust camshaft





Install:
- pulley on the exhaust camshaft according to the marking.
- the 3 screws. Do not tighten. Set the camshaft pulley according to the marking on the upper timing belt cover. Remove the upper timing belt cover.