Cylinder Head, Removing And Installing: Installing

• No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.
• Replace the bolts that were tightened with an additional turn.
• Replace self-locking nuts, sealing rings, seals and the O-rings.
• Grease the contact surfaces between the roller rocker lever and the cam running surface.
• When replacing the cylinder head or cylinder head gasket, all of the coolant and engine oil must be replaced.
• Only unpack the new cylinder head gasket immediately before installing.
• To avoid damaging the cylinder head gasket, handle the gasket very carefully.

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

-- Carefully remove all grinding and sanding residue.

-- Clean oil and coolant residue out of the blind holes for the cylinder head bolts in the cylinder block

-- Before mounting the cylinder head, remove the :T10490  and rotate the crankshaft back opposite the direction of engine rotation until all of the pistons are nearly even under "TDC".

-- Install the alignment sleeves for centering the cylinder block and cylinder head if they are missing.

-- Note the marking on the cylinder head gasket:

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1. Part number
2. Ignore
3. Holes

• If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old cylinder head gasket.
• If sections of the crankshaft were replaced, then the new cylinder head gasket must be determined by measuring the piston projection in "TDC". Refer to PISTON PROJECTION, MEASURING AT TDC .

-- Install the cylinder head gasket on the alignment bushings -arrows- in the cylinder block.

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• Cylinder head seal installation position: Identification "oben" (top) or the cylinder head part number.
• A second technician is needed to install the cylinder head.

-- Set cylinder head in place.

-- Install and tighten the bolts for the cylinder head. Refer to CYLINDER HEAD - TIGHTENING SPECIFICATION AND SEQUENCE '.

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

-- Turn the crankshaft in direction of engine rotation, until the tip -arrow- on the :T10490  fits into the sealing flange.

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-- Install the toothed belt (adjust timing). Refer to TOOTHED BELT, REMOVING FROM CAMSHAFT .

The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the emissions control module. Refer to EMISSIONS CONTROL MODULE, REMOVING AND INSTALLING .

-- Install the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- For the electrical connections and wiring routing. Refer to RELAY CARRIERS, FUSE PANELS AND E-BOXES and to Wiring Diagram.

-- Install the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Change the engine oil. Refer to appropriate service information.

-- Replace the coolant. Refer to appropriate service information..