Cylinder Head Installation
SPECIAL TOOLS- Standard Shaft tool No. 999 1513, or equivalent
- Standard Handle tool No. 999 1801, or equivalent
- Drift tool No. 999 5449, or equivalent
- Crankshaft Locking 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
PROCEDURE
1. Lock crankshaft in position
- Use crankshaft locking tool No. 999 5451, or equivalent, at rear of engine (see illustration).
- Turn crankshaft counterclockwise until counterweight meets stop.
- Check that piston in last cylinder (# 6) is midway between TDC and BDC.
2. Install tappets
- Tappets must be reinstalled in original positions, and oiled
- If tappets have leaked oil, top them up with an oil can or similar via the hole in the side.
3. Install lower cylinder head section
- Use new cylinder head gasket.
- Max. length of M12 head bolts: 158.00 mm
- Oil bolts.
- Tighten head bolts in the sequence shown (starting from center and working outwards) using 3 separate stages:
Stage 1 - Tighten to 20 Nm (15 ft. lbs.)
Stage 2 - Tighten to 60 Nm (44 ft. lbs.)
Stage 3 - Tighten an additional 130°
- Install new O-rings around spark plug wells.
4. Apply liquid sealing compound
- Apply liquid sealing compound part No. 1 161 059-9, or equivalent to camshaft carrier, using short-haired roller tool No. 951 1205, or equivalent.
- Make sure no sealing compound gets into coolant or oil passages.
5. Install camshafts
- Fix camshafts in position using retainer tool No. 999 5453 at front end and locating tool No. 999 5452, or equivalents, (without extension pieces) at rear.
6. Install top cylinder head section
- Place top section in position.
- Tighten it against cylinder head using press tools No. 999 5454 (2 pieces).
- Tighten top section from inside and out to 17 Nm (13 ft. lbs.).
- Remove retainer tool No. 999 5453 and press tools No. 999 5454 or equivalents.
7. Install camshaft front seals
- Use drift tool No. 999 5449 and standard shaft tool No. 999 1513, or equivalents.
- Oil seals.
- Tap seals in place.