Service Information

Document Title: Function Group: Information Type: Date:

Cylinder head, fitting 211 Service Information 2/2/2017 1
Profile:
Engine, D16F (15050684) [GB]

Cylinder head, fitting

Op nbr 211-081

Total procedure time (hr): 1.50

Tools:
885811 Timing tool
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9996239 Lifting chain

1. Clean the contact face as well as sealing surfaces on the cylinder block and the cylinder head.

2. Prepare by installing the pipe from the coolant pump. Remove 9990157 Press tool from the engine block.

Figure 1

3. Apply a 2 mm (0.08 in) thick bead of sealant on the timing gear plate according to diagram.
NOTE!
The cylinder head must be installed within 20 minutes of applying the sealant.

Figure 2
Sealant

4. Install new cylinder head gasket.

NOTE!
Check that the gasket is installed correctly and that all holes are centred.
5. Lower the cylinder head so that it rests on the cylinder head gasket.

Figure 3

6. Maintain a distance to the timing gear plate of 510 mm (0.20.4 in). Guide pins make sure that the cylinder head
ends up in line with the engine block. Weight cylinder head: approx. 210 kg (460 lbs).
NOTE!
The cylinder block's guide pins fit in the keyhole-shaped guide holes in the cylinder head and make sure that the
cylinder head ends up in line with the cylinder block.

Figure 4

1. Guide pin
2. Keyhole-shaped holes

Push the cylinder head against the timing gear plate.

 Figure 5

7. Install an M12 bolt (1) through the timing gear plate and the hub in the camshaft's transfer gear to be able to pull
the cylinder head backwards against the timing gear plate. Tighten the M12 bolt with28 Nm (21 lbf ft), then
loosen the bolt 45 to prevent the bolt from being damaged when the cylinder head bolts are tightened.

Figure 6

8. Lock the cylinder head in position with the cylinder head's bolts 23, 25, 27, and 29, see tightening diagram Engine,
tighten torques. Tighten the four bolts temporarily with 60 +10/5 Nm (44 +7/-4 lbf ft).

9. Tighten the cylinder head's bolts according to tightening diagram. Use 885811 Timing toolTightening torque, see
Engine, tighten torques

10. Tighten the timing gear plate's M8-bolts against the cylinder head. Tightening torque: see Engine, tighten torques
NOTE!
Rotate the engine to access the two bolts behind the camshaft's transfer gear.

Figure 7

11. Install both remaining bolts in the camshaft's transfer gear without tightening them.

12. Continue with: Engine, assembling.