Installing
Installing cylinder head cover - engine removedATTENTION: Damage due to ingress of dirt
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Note: The coated screws for the bearing surfaces of the camshaft in the cylinder head cover must be replaced when installing.
1. Insert three new seals for the spark-plug recesses.
Only the following sealants may be used to seal the cylinder head cover:
^ "Drei Bond" silicone - type 1209
^ Loctite 5900
2. Prepare cylinder head cover for assembly. Apply a thin bead of sealant on the cylinder head cover (not higher than 1.5 mm). Sealant application cylinder head cover
3. Coated screws on the camshaft bearing surfaces -1- must be replaced.
4. Place the cylinder head cover carefully onto the cylinder head. The bead of sealing compound must not be wiped off or interrupted.
5. Position 20 Torx screws (eight of these should be new, coated screws) on the cylinder head cover and tighten according to the specified tightening sequence. Only lightly screw in the two screws in the area of the oil suction pump/tandem pump. They will be tightened after the pump is assembled. Tightening torque 9.5 ft. lbs..
6. Position a new cap o 45 mm (brown) on the bore of the intake camshaft on the pulley side and tap it gently into place with a plastic hammer (dry mount).
7. Insert two new caps (green) into the small bores on the clutch side. Tap it in with a plastic hammer (dry mount).
Note: Replace the O-ring on the oil suction pump (tandem pump).
8. Mount the oil suction pump or tandem pump with four new, micro-self-locking Torx screws -1-. Replace O-rings on the pumps and the vacuum line -2-. Lightly grease O-rings with Optimol MP3. Tightening torque 7.5 ft. lbs..
9. Tighten the two screws on cylinder head cover in area of oil suction pump/tandem pump. Tightening torque 9.5 ft. lbs.
10. Insert the solenoid hydraulic valve, valve lift control on cylinder 4-6 with a new O-ring. Note installation position (plug connection is horizontal).
11. Push on two new retainer plates on the solenoid hydraulic valves on each cylinder row. Position support and tighten with two M6 x 20 Torx socket screws. Tightening torque 7.5 ft. lbs..
^ A: support for camshaft adjustment valve (camshaft timing) + B: support for valve lift adjustment valve (valve lift control)
Retainer plate with integrated gaskets (identical parts)
12. Insert ignition coils into the spark-plug recesses. Position and tighten two M6 x 25 Torx socket screws per ignition coil. Tightening torque 7.5 ft. lbs..
13. Position support for rear muffler with four Torx screws: intake side, two M8 x 30, exhaust side, two M8 x 25, then tighten to the specified torque. Tightening torque 17 ft. lbs.
14. Plug in cable plugs for ignition coils and magnetic hydraulic valves. Secure the cables of the hydraulic valves in the sheet metal clips.
15. Install cover plate, position and tighten two M6 x 16 Torx screws. Tightening torque 7.5 ft. lbs..
Cylinder side 4-6:
16. Connect the two cable plugs on the oil temperature switch.
17. Fasten ground cable on cylinder head with M8 Torx screw. Tightening torque 17 ft. lbs.
Touch up for installing cylinder head cover
1. Fit rear mufflers.
2. Install engine.