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! 

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). Refer to the component overview for tightening specifications.
   Fig 3: Overview Of Cylinder Head (1 To 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 => For tightening specifications, see Figure
   9. Spark plug
   Fig 4: Overview Of Cylinder Head (5 To 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 Figure Tightening Sequence For Cylinder Head.
4. Fit front M8 screw to secure the cylinder head of cylinders 1 to 4 to the crankcase. -3- 
   Fig 5: Overview Of Cylinder Head (1 To 4)

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5. Fit the mounting saddle at the front -8-  (cylinder bank 1 to 4 shown).
   Fig 6: Identifying Camshafts And Cylinder Bank Components (1 To 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. → Tightening torque: 10 Nm (7.5 ft lbs.) 
      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 Clip At Rear Right

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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 Clip 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-  . → Tightening torque: 23 Nm (17 ft lbs.) 
   2. 9.2. Clip in engine wire harness using the retaining clips -arrows B-  .
      Fig 10: Locating Engine Wire Harness Close To High-Pressure Pump

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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-  . → Tightening torque: 10 Nm (7.5 ft lbs.) 
       Fig 11: Installing Vent Line

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11. Insert oil vent line at the firewall side of cylinder 5 and screw it on. Lightly grease the sealing ring.
    Fig 12: Exploded View Of Vent Line

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    1. Vent line to cylinder head/crankcase/oil pump
    2. O-ring
    3. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.) 
    4. Check valve
    1. Direction of travel