Cylinder Head Assembly: Service and Repair
REMOVALNote: Detach cylinder head together with camshaft, intake manifold and exhaust manifold after engine has cooled down.
1. Raise hood to vertical position.
2. Drain coolant at crankcase.
3. Remove front cover at top, Upper Cover.
Marking Camshaft Gear:
4. Mark position of camshaft gear relative to camshaft. This is done by applying colored marking next to fixing pin (3) on the camshaft gear.
5. Remove chain tensioner, Service and Repair.
Cam Gear:
6. Unscrew Camshaft Gear bolts (16).
Installation Note: Tightening torque Hex. socket bolts M6: 11 Nm (8 ft lbs), Torx bolts M7: 16 Nm (12 ft lbs).
7. Pull off camshaft gear (19) by hand.
Withdrawing Slide Rail Pin:
8. Use impact extractor 116 589 20 33 00 to withdraw slide rail pin (74).
Installation Note: The thread in the slide rail pin (74) must be facing forward in direction of travel when it is knocked in.
Dipstick Guide Tube:
9. Unscrew bracket (126) for dipstick guide tube.
Intake Manifold Support:
10. Unscrew intake manifold support (440) at top, detach at bottom.
Coolant Hose:
11. Slacken hose clips (arrow) on the coolant hose to the coolant pump.
Heater Return Line:
12. Slacken hose clip (235). Detach heating water return line (236).
13. If automatic transmission fitted: Unscrew bolt (516).
Fuel Lines:
14. Briefly open fuel filler cap to release the pressure in the fuel tank. Unscrew fuel lines (379, 380). Hold the connection fitting (arrow) to prevent it moving when slackening the fuel line (380).
Bowden Cables:
15. Detach Bowden cable (accelerator control). Press plastic guide (517) out of its seat in the fulcrum lever (390) and withdraw Bowden cable (403) through the slot in fulcrum lever (390). Compress the links of the plastic clip (518) and push plastic clip with the Bowden cable (403) to the rear through the bracket.
Installation Note: Adjust Bowden cable (403).
Kickdown Cable:
16. Detach control pressure cable (396). Compress links (519) of the plastic clip and guide plastic clip with linkage through the bracket.
Engine Wiring Harness:
17. Detach engine wiring harness (39). Slacken all the cable straps of the engine wiring harness (39). Detach all the plug connections along the engine wiring harness (39).
Position Sensor:
18. Detach green control cable and vacuum line at the connector-sensor ignition control unit:
1. Vacuum connection
2. Control line-position sensor connection
3. Connector-sensor connection
Diagnostic Socket:
19. Detach terminal block terminal TD (arrow) next to diagnostic socket (X11), unscrew diagnostic socket (X11), detach grey cable from the TDC sensor on the rear of the diagnostic socket (X11).
Exhaust Flange:
20. Unscrew bolts (arrows) for exhaust system on the flange of the exhaust manifold.
Tightening Sequence:
21. Slacken cylinder head bolts when engine cold in stages in the reverse order to the tightening diagram, starting with 14.
Lifting Cylinder Head Assembly:
22. Attach engine hoist to the suspension lugs of the engine. Take off cylinder head.
INSTALLATION
1. Renew cylinder head gasket.
Installation Note: Pay attention to the 2 fit pins (609) for locating the cylinder head on the crankcase
Camshaft Alignment:
2. Turn crankshaft so that pin (22) or positioning bore of the camshaft is aligned with the marking (517) on the 1st camshaft bearing.
TDC Mark:
3. Position piston of No. 1 cylinder to TDC (arrow).
Checking Cylinder Head Bolts:
4. Check cylinder head bolts.
Note: Each time the cylinder head bolts are tightened they are subject to a certain permanent stretch. If the maximum length (L) of 108.4 mm (4.27 in) is exceeded, the bolts should be scrapped and replaced by new ones.
5. Oil the thread of the cylinder head bolts and also the contact surface of the bolt head and insert.
Tightening Sequence:
6. Tighten the cylinder head bolts in stages in the order shown in the tightening diagram, beginning with 1.
1st tightening stage 70 Nm (52 ft lbs)
2nd tightening stage 90° angle of rotation
3rd tightening stage 90° angle of rotation
7. Install all components in the reverse order of disassembly, paying close attention to torque values and Installation Notes.