Cylinder Head, Removing And Installing: Installing

• Carefully remove the sealant residue from the cylinder head and cylinder block.

• Replace the bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts, gaskets, seals and O-rings after removal.
• Secure all hose connections with hose clamps that match the ones used in series production.
• Only unpack the new cylinder head gasket immediately before installing.
• To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.
• If a replacement cylinder is installed, only remove the plastic base right before cylinder head is installed to protect open valves.
• When installing a replacement cylinder head, the contact surfaces between the roller rocker lever and cam running surface need to be oiled before the cylinder head cover can be installed.
• When replacing the cylinder head or cylinder head gasket, replace all of the coolant and engine oil.
• If the crankshaft was turned in the meantime: bring the piston for cylinder 1 to TDC and then turn the crankshaft back again slightly.
• When turning the crankshaft pay attention that no components are not damaged by the timing chain.

• Carefully remove the sealant residue from the cylinder head and cylinder block.
• Make sure that no long grooves or scratches result.
• Carefully remove all lapping and sanding residue.
• Clean oil and coolant residue out of the blind holes for the cylinder head bolts in the cylinder block
• Position the cylinder head gasket.
  • Pay attention to centering pins in cylinder block -arrows-.

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  • Pay attention to the cylinder head gasket installation position: the part number must be readable from the intake side.
• If the crankshaft was turned in the meantime: bring the piston for cylinder 1 to TDC and then turn the crankshaft back again slightly.
  • When turning the crankshaft pay attention that no components are not damaged by the timing chain.
• Position the cylinder head.
• Install and tighten the cylinder head bolts.

TIP: 

It is not required to retighten the cylinder head bolts after repairs.

Further installation is performed in reverse order of removal, while noting the following:

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• Turn the crankshaft using the -T40263-, -T40314- and the 24 mm socket until the vibration damper is at "TDC".
  • The notch -1- on the vibration damper must align with the arrow marking -2- on the lower timing chain cover.
  • The mark on the lower timing chain cover is located in the »four-o'clock position«.
• Connect the coolant hose to the connector coupling. Refer to OVERVIEW - RADIATOR/COOLANT FAN .
• Install the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .
• Install the spark plugs. Refer to OVERVIEW - IGNITION SYSTEM .
• Change the engine oil. Refer to ENGINE OIL .
• Change the coolant. Refer to COOLANT, DRAINING AND FILLING .

There are additional procedures depending on the model. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .