Cylinder head inspection (page 2 of 9)

Refit

1. Remove timing pin 18G 1523, temporarily fit crankshaft pulley bolt and rotate crankshaft anti-clockwise until numbers 1 and 4 pistons are approximately 25 mm below cylinder block face. Do not remove bolt at this stage.

CAUTION: Ensure timing belt is not trapped as crankshaft is rotated.

2. Position camshaft gear drive pin at 2 o’clock. If necessary, temporarily fit camshaft gear to rotate camshaft; remove gear.

3. Check that oil feed restrictor in cylinder block is clear and fitted below cylinder block top face.
4. Fit new cylinder head gasket, dry, to cylinder block.
5. Fit cylinder head onto cylinder block, carefully locating on dowels, use assistance.

6. Lubricate threads of each cylinder head bolt with engine oil. Fit bolts in their original fitted position and tighten bolts progressively in the sequence shown using the following procedure: i.Tighten all bolts to 30 Nm. ii.Tighten all bolts to 65 Nm. iii.Turn all bolts through 90° . iv.Turn all bolts through another 90° .

CAUTION: Do not drop bolts into position. Do not tighten bolts 180° in one operation.

7. Fit camshaft cover and working in the sequence shown, fit and tighten bolts to 12 Nm.
8. Position timing belt back cover, fit and tighten bolts to 8 Nm.
9. Temporarily fit camshaft gear, rotate camshaft until timing mark is aligned with mark on back cover, remove camshaft gear.
10. Carefully rotate crankshaft clockwise until timing pin 18G 1523 can be inserted in hole in flywheel. Remove pulley bolt.

CAUTION: Do not rotate crankshaft too far, pistons may contact valves.

11. Connect vacuum pipe to vacuum pump and secure with clip.
12. Align vacuum pipe bracket to camshaft cover, fit and tighten Allen screw.
13. Connect feed leads to glow plugs, fit and tighten terminal nuts.
14. Clean mating faces of coolant outlet elbow and cylinder head.
15. Fit new seal to coolant outlet elbow.
16. Position coolant outlet elbow to cylinder head, fit bolts and tighten to 25 Nm.