Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Locking Pin (T40069)

• Camshaft Locator (T40070)

Removing

• Engine installed.

• The following removal and installation procedure is for the left cylinder head. The procedure for the other side is identical.

CAUTION!
Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure.

- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Remove front exhaust pipe. Refer to: Left => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe with Catalytic Converter, right => [ Right Exhaust Pipe with Catalytic Converter ] Right Exhaust Pipe with Catalytic Converter.

- Remove ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt

- Remove front coolant pipe. Refer to => [ Front Coolant Pipe ] Front Coolant Pipe.

- Remove the power steering pump.

• To remove the right cylinder head, the vacuum pump for brake booster must be removed.

- Remove upper section of intake manifold.

- Remove intake manifold lower part.

- Disconnect electrical harness connectors at fuel injectors.

- Disconnect the oxygen sensor connector - 1 - in front of the catalytic converter and free up the wire.





• Ignore - 2 -.

- Remove oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Disconnect fuel line - arrow -.





- Remove the low pressure line, thereby removing bolts and union nuts - 1 through 6 -.





- Remove big lifting eye - arrows -, if equipped.





- Disconnect connectors - 1 - and - 2 -.





- If necessary, remove high pressure pump from left cylinder head - arrows -.

- Remove bolt - arrow - and pull oil dipstick guide tube upward and out.





- Remove cylinder head cove. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Remove left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Remove camshaft timing chains from the camshafts. Refer to => [ Camshaft Timing Chain, Removing from Camshaft, Chain Tensioner ] Camshaft Timing Chain, Removing from Camshaft, Chain Tensioner.

- Remove bolts - arrows - at rear of cylinder head.





• Left cylinder head: 3 bolts.

• Right cylinder head: 4 bolts.

- Follow sequence - 1 to 8 - when loosening cylinder head bolts.





- Carefully remove cylinder head.

Installing

• Replace cylinder head bolts.

• During assembly, replace self-locking nuts and bolts.

• Always replace bolts that are tightened to torque as well as O-rings and gaskets.

• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.

• Carefully remove all grinding and sanding residue.

• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

• Checking cylinder head for distortion. Refer to => [ Checking Cylinder Head for Distortion ] Cylinder Head Assembly Overview.

• Only unpack new cylinder head gasket immediately prior to installation.

• Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage.

• Install cylinder head gasket onto guide sleeves. Marking "oben" (top) or part number must face toward cylinder head.

• After installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller cam followers and cam lubricating surfaces after installing cylinder head.

• Do not remove plastic bases protecting free up valves until immediately before installing cylinder head.

• When replacing cylinder head or cylinder head seal, coolant and engine oil must be changed.

• Secure all hose connections with hose clamps appropriate for the model.

• During installation, all cable ties must be re-installed at the same location.

• After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

- Before installing the cylinder head, set the crankshaft and camshafts to the TDC setting by mounting the Camshaft Locating Tool (T40070) on both cylinder heads and tightening it to 20 Nm.





• The Camshaft Locating Tool (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.

• Crankshaft Holder (T40069) must be screwed into the crankshaft.





- Position cylinder head gasket.

• Pay close attention to centering pins - arrows - in cylinder block.





• Pay attention to installation position of cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.

- Install cylinder head.

- Insert new cylinder head bolts and tighten by hand.





- Tighten cylinder head in sequence indicated, in 3 stages as follows:

- Tighten to 40 Nm.

- Tighten an additional 90°.

- Tighten an additional 90°.

• There is no requirement to retighten the cylinder head bolts.

- Tighten the bolts - arrows - to 9 Nm.





• Left cylinder head: 3 bolts.

• Right cylinder head: 4 bolts.

Further installation is performed in reverse order of removal, noting the following:

- Install the camshaft timing chains. Refer to => [ Installing ] Camshaft Timing Chain, Removing from Camshaft, Chain Tensioner.

- Install left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Install cylinder head cover. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Install high pressure pump.

- Install oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Install intake manifold lower-section with high and low-pressure lines.

- Install intake manifold upper-section.

- Install the brake booster vacuum pump.

- Install the power steering pump.

- Install front coolant pipe. Refer to => [ Front Coolant Pipe ] Front Coolant Pipe.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Install front exhaust pipe with catalytic converter. Refer to: Left => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe with Catalytic Converter; right => [ Right Exhaust Pipe with Catalytic Converter ] Right Exhaust Pipe with Catalytic Converter.

- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.

- Replace engine oil.

- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Fill the power steering fluid and and bleed the steering system.

Tightening Specifications