Cylinder Head, Removing And Installing: Installing

• The use of unpermitted sanding materials can cause subsequent damage, such as turbocharger damage, connecting rod bearing, etc.
• Do not use any sanding materials (sandpaper, sand stone sanding pads, sanding strips, or abrasive cloths etc.).

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• May not be applied on sealing surfaces (see illustration).
• The dark discoloration (see illustration) must not be removed.
• When removing the sealant residue pay attention that no loosened sealant residue gets into the channel to the engine.
• Pay attention to the neighboring work stations cleanliness and that no there is no sanding from above.

-- Clean the sealing surfaces with the corresponding brush from the cleaning set for the sealing surfaces : VAS 294 019  .

• Brush: VAS 294 019/1  for gray cast-iron surfaces
• Brush: VAS 294 019/2  for aluminum surfaces
• Brush: VAS 294 019/3  for painted surfaces

-- Remove any loose residue with a lint-free cloth.

• The sealing surfaces must not be damaged.
• There must be no oil or coolant in the bolt blind holes.
• Only unpack the new cylinder head gasket immediately before installing.
• If a new cylinder head is installed, then oil the contact surfaces between the roller rocker lever and the cam running surface.
• To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.
• To ensure valves do not strike pistons when starting, carefully rotate the crankshaft at least two turns.
• It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.

-- Remove any loose residue with a lint-free cloth.

-- Before mounting the cylinder head, remove the Crankshaft Lock: 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:

Fig 1: 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.

Fig 2: Identifying Cylinder Head Gasket With Alignment Bushings

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

-- Position the cylinder head.

-- Install and tighten the cylinder head bolts. Refer to Figure.

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

-- Turn the crankshaft in the direction of engine rotation, until the pin -arrow- on the Crankshaft Lock: T10490  engages into the sealing flange.

Fig 3: Identifying Crankshaft Lock T10490

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-- Install the toothed belt (adjust valve timing). Refer to Installing (Adjusting Valve Timing) .

Install in reverse order of removal. Note 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 .

-- Electrical connections and routing. Refer to OVERVIEW - RELAY CARRIERS, FUSE PANELS AND E-BOXES and the appropriate 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 ENGINE OIL, DRAINING , ENGINE OIL FILTER, REPLACING , ENGINE OIL, FILLING or ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY .

-- Change the coolant. Refer to Fill And Bleed The Coolant Circuit .