Cylinder Head, Installing, 2.9L Engine: Procedure

• Do not use any sanding materials (sandpaper, sand stone sanding pads, sanding strips, or abrasive cloths etc.).
• May not be applied on sealing surfaces.
• The dark discoloration does not need to 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.
• The use of unpermitted sanding materials can cause subsequent damage, such as turbocharger damage, connecting rod bearing, etc.

-- Remove the cylinder head sealing residues and the cylinder block using the Contour Blade Set :VAS 852 005  or a commercially available blade scraper (width at least 40 mm).

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

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

• Carefully remove the sealant residue from the cylinder head and cylinder block.
• Make sure that no long grooves or scratches result.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• 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.
• Replace bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts, gaskets, seals and O-rings after removal.
• The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.
• 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.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Electronic Parts Information (ETKA).
• Check the vacuum hoses for damage before the assembly and replace if necessary.
• When replacing the cylinder head or cylinder head gasket, replace all of the coolant and engine oil.

-- Check if the check valve for the coolant -arrow- is inserted in the cylinder head. (Shown on cylinder bank 2.)

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-- Check whether the alignment sleeves -arrows- are inserted in cylinder block. (Shown on the bank 2 cylinder block.)

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-- Clean any oil or grease off the sealing surfaces.

• Be sure to check the expiration date of the sealant.
  Fig 1: Cut Tube Nozzle At Front Marking

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-- Cut the tube nozzle at the front marking (nozzle diameter: about 2.0 mm).

Cylinder Bank 1 (Right):

-- Apply sealant beads -1 and 2- as shown on the clean sealing surfaces of the cylinder block and the lower timing chain cover.

• Sealant bead thickness: 2 mm.

Cylinder Bank 2 (Left):

-- Insert the new bolt -left lower arrow- and install the left intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- Apply sealant beads -1 and 2- as shown on the clean sealing surfaces of the cylinder block and the lower timing chain cover.

• Sealant bead thickness: 2 mm.

Continuation for Both Sides:

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

• Cylinder head gasket installation position: "oben" (top) marking or part number toward the cylinder head.

-- Position the cylinder head.

-- Install the cylinder bolts all the way in by hand.

-- Tighten the cylinder head bolts.

TIP:

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

Install in reverse order of removal. Note the following:

-- Install the right intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- Install the coolant pipes. Refer to COOLANT PIPES, REMOVING AND INSTALLING .

-- Install the turbocharger. Refer to TURBOCHARGER, REMOVING AND INSTALLING .

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

-- Change the engine oil. Refer to ENGINE OIL .

-- Change the coolant. Refer to COOLANT, DRAINING AND FILLING .

Additional procedures depending on the model: CYLINDER HEAD, REMOVING AND INSTALLING .