Installing Cylinder Head

Information 

If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can occur because of condensed water forming or components distorting. Components must have a uniform temperature of at least 17°C.

Information 

• All sealing surfaces must be clean and free of grease! 
• It is essential to work carefully! 
• Tightening sequences and tightening torques must be observed! 

Information 

The tightening specifications for the basic engine are stored centrally.

> 1X00IN TECHNICAL VALUES

/

> 2X00IN TECHNICAL VALUES

or

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS .

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

1. Replace cylinder head gasket.
2. Place cylinder head gasket correctly, i.e. according to specifications, onto the straight pins on the engine crank housing. This must be done in such a way that the marking 'Top' is legible - see illustration-  .

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   Cylinder bank 1 -4

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   Cylinder bank 5 - 8

3. Fit cylinder head. Insert cylinder head screws (screws can be re-used). For tightening specifications, see > 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
   Fig 1: Cylinder Head 1 To 4 Components Location

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   Cylinder head 1 to 4

   1	Cylinder head 1 to 4
   2	Cylinder head gasket 1 to 4
   3	M8 screw
   4	Lid
   5	Stopper
   6	Stopper
   7	Restrictor for valve lift adjustment
   8	Cylinder head screws
   9	Spark plug

   Fig 2: Cylinder Head 5 To 8 Components Location

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   Cylinder head 5 to 8

   1	Cylinder head 5 to 8
   2	Screw plug
   3	Spark plug
   4	Cylinder head gasket 5 to 8
   5	Stopper
   6	Restrictor for valve lift adjustment
   7	Stopper
   8	Lid
   9	Cylinder head screws => For tightening specifications, see Tightening sequence for cylinder head

4. Fit front M8 screw to secure the cylinder head of cylinders 1 to 4 to the crankcase. -3- 

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   Cylinder head 1 to 4

5. Fit the mounting saddle at the front -8-  (cylinder bank 1 to 4 shown).
   Fig 3: Camshafts Components Location - Cylinder Bank 1 To 4

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   Camshafts, cylinder bank 1 to 4

   1	Camshaft (outlet)
   2	Camshaft (intake)
   3	Hydraulic valve for variable valve lift control
   4	Screw, M5 x 12
   5	Switching tappet (oil with engine oil)
   6	Bucket tappet (oil with engine oil)
   7	Stopper
   8	Mounting saddle 1 to 4
   9	Stopper
   10	Bearing locations (oil with engine oil)
   A	Direction of travel

6. Secure wire harness to the engine.
   1. 6.1 Position and lay engine wire harness on the engine housing -arrow-  .
   2. 6.2 Tighten fastening screws.

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   Securing engine wire harness on engine housing

7. Clip in engine wire harness at the rear right using the retaining clip -arrow-  .

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   Clipping in engine wire harness at the rear right

8. Clip in engine wire harness close to the vacuum pump.
   1. 8.1 Clip in engine wire harness using the retaining clip -arrow A-  .
   2. 8.2 Slide engine wire harness onto the holder -arrow B-  .

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   Clipping in engine wire harness close to the vacuum pump

9. Clip in engine wire harness close to the high-pressure pump.
   1. 9.1 Screw in and tighten the screw socket -arrow A-  .
   2. 9.2 Clip in engine wire harness using the retaining clips -arrows B-  .

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   Clipping in engine wire harness close to the high-pressure pump

10. Install vent line.
    1. 10.1 Position vent line -1-  and clip it into the cable duct -arrow-  .
    2. 10.2 Fit the fastening screws -2-  .

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    Vent line