Installation

CAUTION: It is vital to the life of the engine after regrinding of the cylinder head that proper deburring is carried out. Use emery cloth to remove all burrs and to ensure that the edges round the combustion chambers are gently rounded.

NOTE: The method described applies to a car equipped with water-cooled turbo, intercooler, AC, automatic transmission, catalytic converter, two-stage cooling fan and automatic belt tensioner. The procedure needs to be adapted as appropriate to suit cars to different specifications.

NOTE: A redesigned cylinder head has been introduced as a running change on B202 (16-valve) engines starting with Engine Number J082586. The new cylinder head has oil passages drilled into the head casting, thereby eliminating the external oil pipes and fittings previously used to supply oil to the camshafts and lifters. The new cylinder head has also been introduced into the spare parts system for replacement use on earlier 16-valve engines when existing stocks are depleted. No special procedures or parts are required to install the new design head on an earlier car. The same cylinder head bolts and bolt torque specifications are used.

*** FOR ADDITIONAL INFORMATION NOT INCLUDED HERE, REFER TO TSB #08881067, DATED AUGUST, 1988 ***.

NOTE: A new cylinder head gasket (part number 75-61-301) eliminates the requirement of retorquing the cylinder head after the engine has been warmed up and allowed to cool down, retorquing at 1000 miles is also unnecessary.
Earlier type replacement gaskets (part number 75-16-529) still require that the cylinder head be retorqued after the engine has been warmed up and allowed to cool down. If this cool down and retightening takes place, retorquing at 1000 miles is unnecessary.

*** FOR ADDITIONAL INFORMATION NOT INCLUDED HERE, REFER TO TSB #0987995, DATED SEPTEMBER, 1987 AND TSB #0986885, DATED SEPTEMBER, 1986 ***

1. Thoroughly clean all the flanges and fit new gaskets. Use a few drops of gasket sealant or the like to hold the gasket onto the inlet-manifold flange.

2. Check that the camshafts are lined up with their respective timing marks and that the "O"degree mark on the flywheel is in line with the timing mark on the end plate.
3. Thread the timing chain over the pivoting chain guide and carefully lower the cylinder head onto the locating pins.

Tightening Sequence For Head Bolts:

4. Install the head bolts, and tighten them in the sequence shown, to the torque:
Stage I 60 Nm (44 ft lb)
Stage II 80 Nm (59 ft lb)
Stage III Tighten a further quarter-turn ("90"degree)

5. From underneath, install the two bolts securing the timing cover to the cylinder head.

6. Install the camshaft sprockets (exhaust side first), leaving the centre-bolts slack. Check that the chain is correctly seated on the sprocket teeth and in the guides. Fit the chain tensioner. Service and Repair

7. Rotate the crankshaft two complete turns and check that the timing marks on the camshafts and flywheel are still in alignment. Install the centre-bolts in the camshaft sprockets and torque the bolts to 65 Nm (48 ft lb).
8. Install the inlet manifold to the cylinder head and tighten the steady bars.

9. Install the split rubber plugs in the cylinder head. Apply a bead of Permatex Ultra Blue silicone sealant (part no 45-3O 2O 856), 4mm thick, as shown. Fit the camshaft cover. Tighten the bolts to the torque 22 Nm (16 ft lb), starting with those at the distributor and the middle bolt at the other end.

10. Tighten the torque-arm bracket to the cylinder head.

11. Install the fuel-pressure sensor.

12. Reconnect the hose to the temperature sensor and the hose from the heater box to the thermostat housing.

13. Checking first that the rotor is in line with its timing mark install the distributor. Fit the distributor cap and connect the vacuum hose.
14. Reconnect the HT leads to the spark plugs and install the inspection cover. Reconnect the crankcase breather hose.

15. Install the exhaust manifold and turbo assembly, using a new gasket.

16. Install the oil supply pipe and the clip.

17. Install the turbo's top cooling pipe as follows:
- Connect the hose to the outlet on the cylinder head (underneath the inlet manifold) and tighten the hose clip.
- Secure the pipe in the clip on the exhaust manifold.
- Reconnect the pipe to the compressor.
17. Alternative method:
- Reconnect the cooling pipe and hose and tighten the hose clip.
18. Install the turbo oil-return pipe and bracket.

19. Connect the crankcase breather hose to the turbo inlet hose and the throttle-housing preheater hose to the turbo's oil supply pipe.

20. Install the turbo's bottom coolant pipe.

21. Install the rubber socket connector for the turbo delivery pipe to the throttle housing and connect the top coolant hose to the engine.

22. Connect the turbo inlet hose to the compressor and the solenoid-valve hoses to the wastegate valve and turbo compressor.

23. Connect the turbo delivery pipe to the turbo unit.

24. Secure the exhaust pipe to the turbo unit.

25. Lift the fan into position and tighten the top fixing screws. Plug in the electrical connectors.

26. Install the solenoid valve.

27. Reconnect the Lambda-sensor leads, install the two clips and secure the lead by means of a tie to the engine lifting lug.

28. Install the AC-compressor bracket to the cylinder head and block.
29. Install the AC-compressor.

NOTE: when instaling, leave the coolant hose in the bracket and connect it to the spigot on the water pump. Tighten the bolts. Plug in the connector. Check to make sure that the lead is well clear of the pulley.