Cylinder Head, Remove and Install
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Only remove cylinder head when engine is cold; oil temperature at approximately 20 °C / 68 °F.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
|---|---|---|---|
| Exhaust pipe from manifold. | |||
| .P. U0527.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Negative cable from battery. | |||
| .P. C6112.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Air intake hose. | |||
| .P. U0534.tif | 9 | 7,5 | tiff;; |
Drain radiator - collect coolant.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
All coolant hoses to thermostat housing and water pump.
Vacuum lines.
Accelerator cable.
Wiring plugs from injector valves, throttle valve potentiometer.
| Ground cable from intake manifold. | |||
|---|---|---|---|
| .P. U0525.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Fuel lines - identify for installation.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
|---|---|---|---|
| Fuel lines may be under pressure. | |||
| .P. U0526.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Crankcase ventilation from intake manifold.
Cylinder head cover.
| All spark plug connectors. | |||
|---|---|---|---|
| .P. C6117.tif | 9 | 7,5 | tiff;; |
Bring No. 1 cylinder to TDC - recess of camshaft to be in position shown in illustration.
| Ball in flywheel must align with pin on cylinder block. | |||
|---|---|---|---|
| .P. C6118.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Timing gear front cover from cylinder head.
Plastic limitation bolt from camshaft.
| Camshaft timing gear from camshaft - use Splined Wrench MKM - 320. | |||
|---|---|---|---|
| .P. C6119.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Bolts securing timing case to cylinder head. | |||
| .P. C6120.tif | 9 | 7,5 | tiff;; |
To loosen rear cylinder head bolts shorten Allen key SW 10 to
A = 73 mm / 2.9 in.
| B = 103 mm / 4.0 in. | |||
|---|---|---|---|
| .P. C6121.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Rear right cylinder head bolt using short key (A).
Rear left cylinder head bolt long key (B).
| Loosen all cylinder head bolts spirally from outside inwards; first a ¼ turn, then a ½ turn. | |||
|---|---|---|---|
| .P. C6122.tif | 9 | 7,5 | tiff;; |
Loosen cylinder head from cylinder block using mounting lever.
Lift cylinder head out of engine compartment.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
|---|---|---|---|
| Avoid damage to throttle valve switch and valve. | |||
| .D. ICON05.tif | 0,75 | 0,75 | tiff;; Clean |
Sealing surfaces of cylinder block - flat scraper.
Bores of cylinder head bolts - compressed air.
| Cylinder head - flat scraper and compressed air. | |||
|---|---|---|---|
| .P. C6124.tif | 9 | 7,5 | tiff;; |
Apply an approx. 3 mm / 0.1 in. bead of Adhesive Compound 15 03 294 (90 001 851) to left and right of joint between cylinder block and timing case.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
New rubber ring (A) in recess.
New gasket on cylinder block.
| Cylinder head - note guide sleeves. | |||
|---|---|---|---|
| .P. C5983.tif | 9 | 7,5 | tiff;; |
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Use new cylinder head bolts.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
New cylinder head bolts - initially tighten.
| .D. ICON10.tif | 0,75 | 0,75 | tiff;; Torque - Angle Method |
Cylinder head bolts - in sequence shown.
Initially to 60 Nm / 44 lbf ft.
| Further 90° in same sequence - use KM - 470 - B. | |||
|---|---|---|---|
| .P. U0530.tif | 9 | 7,5 | tiff;; |
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Rear right and left cylinder head bolts cannot be tightened by 90° in one turn, tighten each bolt 3 x 30°.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Cylinder head to timing case bolts - 25 Nm / 18 lbf ft. | |||
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Camshaft timing gear - ensure that marks on camshaft timing gear and timing gear support align, and ball in flywheel aligns with pin on cylinder block.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Timing gear bolts - 25 Nm / 18 lbf ft. | |||
| .P. C5989.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
New plastic limitations bolt and cover.
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Play between stop surfaces of cover and plastic limitation bolts - use feeler gauge Maximum permitted play - 0.1 to 0.2 mm / 0.004 to 0.008 in.
| To correct larger play, remove cover and adjust at stop surface with blunt drift. | |||
|---|---|---|---|
| .P. C5990.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
New seal to cylinder head cover - use Pattex to secure seal at rear, ensure area is degreased.
Head cover - use long screws for brackets.
Spark plug connectors.
Crankshaft ventilation to intake manifold.
Fuel lines.
Ground cable to intake manifold.
Wiring pump to injector valves, throttle valve potentiometer.
Accelerator cable.
| Vacuum lines. | |||
|---|---|---|---|
| .P. C6128.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Coolant hoses - ensure hose clamps are installed as shown to avoid damage to engine.
Air intake hose.
Front exhaust to manifold - use MoS2 Paste 19 48 524 (90 001 825) on bolts.
| Negative cable to battery. | |||
|---|---|---|---|
| .P. C6129.tif | 9 | 7,5 | tiff;; |
Top up and bleed coolant system - see corresponding operation.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Cylinder head cover.
| .D. ICON10.tif | 0,75 | 0,75 | tiff;; Torque - Angle Method |
Cylinder head bolts - further 30° to 40°.
| Loosen cylinder head to timing case bolts. | |||
|---|---|---|---|
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Cylinder head to timing case bolts - 25 Nm / 18 lbf ft.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
|---|---|---|---|
| Cylinder head cover. |