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Attaching Parts – Cylinder Head, Remove and
install
 Remove
For Z 20 LET engine: Detach turbocharger with exhaust manifold
from cylinder head.
Detach exhaust manifold from cylinder head.
Remove intake manifold from cylinder head.
Detach thermostat housing and coolant flange from cylinder
head.
Remove spark plugs with KM-194-E.
Caution
Note marking before dismantling camshaft bearing cover!
The camshafts must be uniformly released from the bearing
seats.
Remove
Detach intake camshaft bearing caps working in inward spiral
from outside in steps of 1/2 up to 1 turn.
Detach camshaft bearing caps from cylinder head and remove
intake camshaft.
Edge out camshaft seal rings with suitable tool – ensure
that sealing surfaces are not damaged.
 Clean
Remove gasket residues and clean sealing surfaces.
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Remove
Remove hydraulic valve lifters from cylinder head with KM-845
and lay aside in sequence, so that hydraulic valve lifters can be
allocated to valves on reinstallation.
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Place hydraulic valve lifter to one side in installation
position.
Clean
Clean all removed parts. Clean all sealing surfaces.
Install
Coat hydraulic valve lifter with engine oil and insert in
cylinder head in correct sequence.
Coat sliding surfaces of hydraulic valve lifters and camshaft
with MoS 2 lubricating paste (grey). Insert
camshafts into cylinder head.
Caution
Code numbers on camshaft bearing caps must match those on
cylinder head.
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Apply surface sealant (green) to sealing surfaces of guide
bearings (arrows).
Install
Install camshaft bearing cover at cylinder head and tighten in
spiral pattern from inside outwards – tightening torque 8 Nm
/ 6 lbf. ft.
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Coat sealing lips of the new camshaft seal rings with silicon
grease (white). Press camshaft seal rings in camshaft bearing cap
using KM-422 – use bolt and washer of the camshaft
pulley.
Install spark plugs with KM-194-E into cylinder head –
tightening torque 25 Nm / 18 lbf. ft.
Attach thermostat housing to cylinder head with new seal ring
– tightening torque 15 Nm / 11 lbf. ft.
Attach coolant flange to cylinder head with new gasket –
tightening torque (M8) 20 Nm / 15 lbf. ft, (M10) 30 Nm / 22 lbf.
ft.
Attach intake manifold to cylinder head with new gasket and new
fastening nuts – tightening torque 22 Nm / 16 lbf. ft.
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For Z 20 LET engine: Attach exhaust manifold to cylinder head
with new gasket and new fastening nuts.
Torque
Step 1 – Tighten exhaust manifold in sequence shown
– tightening torque 8 Nm / 5.9 lbf. ft..
Caution
5 minutes waiting time.
Torque
Step 2 – Install exhaust manifold in sequence shown
– tightening torque 8 Nm / 6 lbf. ft.
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For X 20 XER engine: Attach performance header to cylinder head
with new gasket and new fastening nuts.
Torque
Tighten fastening nuts from outside inwards – tightening
torque 22 Nm / 16 lbf. ft.
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For X 20 XEV engine: Attach exhaust manifold to cylinder head
with new gasket and new fastening nuts.
Torque
For version with single-layer gasket – 22 Nm / 16 lbf.
ft.
For version with multi-layer metal-layer gasket:
Step 1 – in the sequence 9 7 8 2 4 3 9 7 2 4 – 14 Nm
/ 10 lbf. ft.
Step 2 – in the sequence 1 2 3 4 5 6 7 8 9 10 – 22
Nm / 16 lbf. ft.
Step 3 – in the sequence 1 2 3 4 5 6 7 8 9 10 – 22
Nm / 16 lbf. ft.
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