Edmunds Answers

Answers

  • MrShift@Edmunds 12/16/12 11:20 pm PST

    Tighten bearing caps 2 and 4 alternately and diagonally. Tightening torque: 20 Nm (15 ft. lbs.)

    Lightly coat bearing cap 1 contact surfaces with sealant AMV 174 004 01.

    Install bearing caps 3, 1 and 5 and tighten. Tightening torque: 20 Nm (15 ft. lbs.)

    Install camshaft sprocket and tighten by counterholding sprocket using 3415 counter-hold (Remove bolts from holes -arrows- before using tool). Tightening torque: 100 Nm (74 ft. lbs.)



    CYLINDER HEAD

    Always replace cylinder head bolts.
    There must NOT be any oil or coolant in the bolt pockets in the cylinder head or there is the danger of creating a hydro-lock while torquing which could lead to structural damage.
    Only remove the new cylinder head gasket from its packaging immediately before installing.
    Handle the new gasket with extreme care. Damage will lead to leaks.
    Place a clean cloth over the cylinders so no dirt or abrasive particles can get between the cylinder wall and piston.
    Take whatever precautions are necessary to prevent dirt and abrasive particles from gaffing into the coolant system.
    Carefully clean the cylinder head and cylinder block sealing surfaces, ensuring that no scores or scratches are formed. When using abrasive paper, do NOT use any grades coarser than 100, such as 80.
    Carefully remove all traces of metal particles, emery remains and cloth.
    Position cyl. 1 piston to top dead center, then turn back crankshaft slightly.

    Center 3450/2A guide pins into head bolt holes


    The tolerance of centering bores was restricted in upper section. Check if locating pins can be pulled up before reinstalling cylinder head. Grind knurl of location pins if necessary.
    Install new cylinder head gasket.
    Lettering (part number) must be readable.
    Install cylinder head, screw in 8 remaining head bolts and tighten by hand.
    Unscrew 3450/2A guide pins through bolt holes using 3450/3 pin driver by turning it counter-clockwise until pins are free.
    Install remaining cylinder head bolts and tighten hand-tight.

    Tighten cylinder head in sequence (below) as follows:
    Pretighten all bolts to 40 Nm (30 ft. lbs.) .
    Tighten all bolts 1/4 turn (90°) further using a box wrench.
    Tighten all bolts a 1/4 turn (90°) further.

    SEQUENCE:

    10 4 2 6 8
    7 5 1 3 9

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