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 be uniformly at least → Temperature: 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 (→ 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, 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 Fig 1-.
   Fig 1: Identifying Cylinder Bank (1-4)

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   Fig 2: Identifying Cylinder Bank (5-8)

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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 3: Identifying Cylinder Head (1-4)

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   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 4: Identifying Cylinder Head (5-8)

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   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, See Figure
4. Fit front M8 screw to secure the cylinder head of cylinders 1 to 4 to the crankcase. -3- 
   Fig 5: Identifying Cylinder Head (1-4)

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5. Fit the mounting saddle at the front -8-  (cylinder bank 1 to 4 shown).
   Fig 6: Identifying Camshafts, (Cylinder Bank 1-4)

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   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)
   1. 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.
      Fig 7: Securing Engine Wire Harness On Engine Housing

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7. Clip in engine wire harness at the rear right using the retaining clip -arrow-  .
   Fig 8: Locating Engine Wire Harness

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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-  .
      Fig 9: Locating Engine Wire Harness Close To Vacuum Pump

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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-  .
      Fig 10: Installing Engine Wire Harness

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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-  .
       Fig 11: Locating Vent Line

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