Cylinder Head, Reassembly/Installation
Cylinder Head, Assembly/Installation
Special tools: 5021, 5025, 5098, 5222, 5379, 5971, 9696, 998 6052
Check valve stem height
Use gauge 5222 and sliding callipers.
Place camshaft carrier on cylinder head.
Place gauge across camshaft bearing seats.
Measure valve stem height by inserting callipers through hole in gauge.
Valve stem height: 49.4 ± 0.4 mm (1.9449 ± 0.0157 in)
Max. machining allowance: 0.4 mm (0.0157 in)
Length, new valve:
Intake 122.45 ± 0.2 mm (4.8209 ± 0.0079 in)
Exhaust 122.25 ± 0.2 mm (4.8130 ± 0.0079 in)
NOTE: Correct valve stem height is essential to satisfactory operation of hydraulic tappets.
Install:
- lower valve spring collars
- valves (in correct positions), oiling valve stems and guides
- intake and exhaust valve stem seals
Always use protective sleeve included in gasket set.
Place sleeve over valve stem.
Push down seal onto stem.
Remove protective sleeve.
Press home seal using assembly tool 5379.
Install:
- valve spring and upper spring collar, using clamp 998 6052
- collets
Install:
- thermostat and thermostat housing
- temperature sensors and pipe branch
Note: Use new gaskets on thermostat and ignition/fuel system temperature sensor unit.
Install:
- new cylinder head gasket
- new 0-ring seal for water pump
Important: Check that No.1 and No.4 pistons are at TDC.
Place cylinder head in position
Lower head carefully into position over guides, taking care to avoid damaging gasket.
Tighten cylinder head bolts
Use protractor 5098.
Oil bolts.
Insert and tighten bolts in three stages, in order shown.
1 = 20 ± 2 Nm (15 ± 1.5 ft.lb)
2 = 40 ± 5 Nm (30 ± 4 ft.lb)
3 = Tighten through further 115 ± 10°.
Apply liquid sealing compound
Apply compound (PIN 1 161 059-9) to joint between camshaft carrier and cylinder head, and to bearing cap joint faces (1, 5 and 6).
Apply compound with a short-haired roller.
Note: Remove excess compound from oilways prior to reassembly.
Install camshaft carrier
Fit new 0-rings in grooves around spark plug wells.
Position camshaft carrier on cylinder head and replace nuts 1, 2, 4 and 5 in center joint.
Plug openings around spark plug wells with paper.
If camshafts have been replaced:
Check camshaft end float
Use dial gauge 9684, magnetic stand 9696 and magnetic base 5971.
Place camshafts in position.
Install rear bearing caps and tighten nuts. Move camshaft to one end limit, read dial gauge, move to other end limit and repeat reading.
End float: 0.05-0.40 mm (0.0020-0.0157 in).
Oil components
Oil bearings and sliding surfaces on camshaft carrier, bearing caps, camshafts and tappets.
Insert tappets
Tappets must be replaced in original order.
Install exhaust side camshaft
Use press tool 5021.
Place camshaft in camshaft carrier with pulley guide pin pointing upwards.
Press camshaft into place with press tool 5021.
Install bearing caps.
Install bearing cap nuts in stages.
Remove press tool 5021 and install center bearing cap (8).
Install intake side camshaft
Use press tool 5021.
Place camshaft in camshaft carrier with pulley guide pin pointing upwards.
Press camshaft into place with press tool 5021.
Install bearing caps.
Install bearing cap nuts in stages.
Remove press tool 5021 and install center bearing cap (3).
Install camshaft carrier center nut.
Tighten camshaft carrier nuts (5) and all bearing cap nuts
Use torque wrench to tighten nuts in center joint and on all bearing caps.
Tighten to 20 Nm (15 ft.lb).
Seal front and rear camshaft bearing caps
Use silicone sealer (P/N 1161 277-7)
Apply bead of sealer to angle between cap and joint face.
Install new gaskets and replace valve cover
Inspect rubber seal behind camshaft on exhaust side.
Position spark plug well gasket with arrow pointing to No.1 cylinder and marking facing upwards.
Shape outer gasket to fit camshaft bearing caps. Place gasket in position and install valve cover.
Install camshaft seals
Use assembly tool 5025.
Grease seals.
Press in seals.
Note: Camshafts must not be allowed to rotate when fitting seals. Face of seal should normally be flush with chamfered edge in camshaft carrier. However, if shaft end shows signs of wear, seal may be located approx. 2 mm further in.
Fill engine with oil
Capacity 4.0 L (4.2 US qt.)
Oil level must be checked/topped up after engine has been run at working temperature.
Pump oil into lubrication system
Run oil pump clockwise for about 1 minute using nut runner.
Turn drive pulley by hand to verify that pressure has been established.
Pump rotor should offer variable resistance to rotation.