Cylinder Head, Removing

Cylinder head, removing

^ Engine in vehicle

Note:
^ Secure all hose connections with the correct hose clips (same as original equipment)

^ All cable ties which are opened or cut open when removing must be replaced in the same position when installing.

- Obtain radio anti-theft code on vehicles with coded radio.
- With ignition switched off disconnect battery Ground strap.
- Drain cooling system.
- Remove intake manifold.
- Disconnect coolant line from thermostat housing only.
- Unbolt coolant line flange from cylinder head (left) and place it to one side.
- Disconnect connectors on ignition coils.
- Unclip/release all lines and hoses on cylinder head and move clear.





- Disconnect air hose -1- from upper air line.
- Unbolt retainer for oil return line -2-.
- Release hose -4- from upper air line (hose leads to turbocharger).
- Remove bolts -1- and -5- for heat shield on back of cylinder head.
- Remove bolts -2- and -3- for upper air line.
- Remove upper air line and heat shield.
- Unbolt turbocharger from exhaust manifold.
- Remove ribbed belt and tensioning element.
- Remove toothed belt guard (upper).





- Set crankshaft to markings for TDC of No. 1 cylinder (arrows) by turning central bolt on crankshaft sprocket in direction of rotation.





- Remove bolts (left arrows) and remove coolant expansion tank together with hoses.
- Remove bolt (right arrow) and remove power steering reservoir. Do not disconnect hoses.





- Screw M5 x 55 stud -1- into toothed belt tensioning element.
- Screw hex nut -2- onto stud -1- using large washer -3-.
- Tension pressure piston of tensioning element only until it can be secured with a locking pin (e.g. from lifting appliance 2024 A) arrow-.

Note:
If it is not possible to insert the locking pin, carefully tension the pressure piston of the tensioning element just enough to allow the toothed belt to be removed.

- Take toothed belt off camshaft sprocket.
- Unbolt ignition coils.
- Remove cylinder head cover.





- Maintain sequence when loosening and tightening cylinder head bolts.
- Remove cylinder head.