Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Ignition Coil Puller (T40039)
• Assembly Tool (T10352/1)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• Drift (T40196)
• Engine Bung Set (VAS 6122)
Removing
• During installation, cable ties must be installed at the same location.
• Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the (VAS 6122).
- Remove the front noise insulation.
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.
- Drain coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.
- Remove the front muffler. Refer to => [ Front Muffler ] Front Muffler.
- Remove the engine cover - arrows -.
- Remove the coolant hoses on the back of the cylinder head.
- Remove the air duct - arrows -.
- Disconnect the connector - 2 - from the mass airflow (MAF) sensor (G70).
- Open the clamp - 3 - and remove the air guide tube from the mass airflow (MAF) sensor.
- Remove the air filter housing - 1 - upward.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Risk of contamination to the fuel system.
• Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect fuel supply hose - 1 - by pressing release ring.
- Remove the hose - 2 - from the EVAP canister.
- Remove the bolts - 1 - and nuts - 2 - and - arrow - and remove the strut tower brace.
- Remove the left and right foam block - 1 - and - 2 -.
- Remove gasket - 3 -.
- Open the clips - 1 - and remove the plenum chamber cover - 2 -.
- Disconnect the vacuum connection - 1 - from the plenum chamber bulkhead by remove the vacuum hose - 2 - on the back side - arrow -.
- Remove the front bumper cover and bumper. Refer to Description and Operation.
- Perform a service position.
- Loosen the hose clamps - arrows - and remove the air guide hose.
- Disconnect the following connectors.
2 Disconnect from knock sensor 1 (G61)
3 From the intake manifold runner control valve (N316) , fuel pressure sensor (G247) and camshaft position sensor (G40).
4 From the fuel injectors
5 From the throttle valve control module (J338).
6 From the intake air temperature sensor (G42).
- Disconnect connector - 2 - and free up the wire.
- Remove the coolant line bracket - arrow -.
• The engine is not shown in the illustrations that follows.
- Remove the intake manifold bracket by removing the mounting nut - 1 - and bolt - 2 -.
- Disconnect the coolant hose - arrow -.
- Remove the bolts - 1 and 2 - and move the oil supply line to the side.
- Remove the bolt - 3 - and move the coolant line to the side.
- Loosen the hose clamp - arrow -, pull the air guide hose and move it to the side.
- Disconnect the connectors - 1 and 4 - from the oil pressure switch and remove the reduced oil pressure switch.
- Disconnect the connectors - 1 and 2 - and free up the electric wire.
- Remove the bolts - arrows - and then remove the turbocharger support.
- Remove the bolts - arrows - on the oil return line.
- Remove the nuts - arrows - and push the catalytic converter to the rear.
- Disconnect the connector from camshaft adjustment valve 1 - 1 -.
- Remove the bolts - arrows - and the camshaft adjustment valve 1.
- Remove the bolts - 1 through 5 - and remove the timing chain upper cover.
- Remove the bolts on the ignition coil connector strip.
- Release the connector - arrows - and disconnect all the connectors at the same time from the ignition coils.
- Remove the ignition coils using the (T40039).
- Remove the spark plugs using (3122 B).
- Disconnect the hose for the crankcase ventilation - 1 -.
- Remove the bolts - arrows - and then remove the crankcase ventilation from the hose - 2 - in direction of - arrow -.
- Disconnect the connectors - arrows - from the camshaft adjuster actuators.
- Remove the camshaft adjuster actuators - arrows -.
- Turn the sealing plug - arrows - counterclockwise 90° in the direction of the - arrow - and remove it.
- Remove the ball head - 1 through 2 -.
- Remove the cap.
- Turn the vibration damper to "TDC" - arrow - with the (T10355).
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
• The markings - 1 - on the camshafts must point upward.
- Remove the cylinder head bolts - 1 and 2 -.
The engine could be destroyed.
• The (T40196) may be installed only in the shown positions.
- Install the (T40196) as illustrated.
- Turn the crankshaft 4 complete turns in the direction of engine rotation.
- Remove the (T40196).
The control valve has a left thread.
- Remove the control valve in direction of - arrow - using the assembly tool (T10352/1).
- Remove the bolts - arrows - and remove the bearing bracket.
- Turn the vibration damper to "TDC" - arrow - using the (T10355).
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
- Mark the camshaft timing chain and the cylinder head - arrows - to match the marking on the chain sprockets - 1 - with a waterproof marker.
- Remove the plug - arrow -.
- Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner in direction of - arrow 1 -.
- Turn the crankshaft opposite the engine direction of rotation - arrow 2 - and secure it with a (T40011).
• The intake camshaft switches in the engine direction of rotation.
- Remove the bolt - 1 - and guide the tensioning rail - 2 - downward.
- Remove the upper guide track - 3 - by unlocking the latch with a screwdriver and pushing the guide track forward.
- Remove camshaft timing chain from chain sprockets.
Risk of damaging valves and piston crowns.
• If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.
- Remove the bolts - arrows -.
- Remove the cylinder head bolts in a - 1 to 8 - sequence.
• To remove the cylinder head bolts, turn the camshaft with a wrench if necessary.
• Make sure all wires and cables are disconnect!
• Pay attention to the tension and guide tracks when lifting the cylinder head.
- Remove the cylinder head.
- Lay the cylinder head on a soft surface, such as foam.
Installing
• Tightening specifications, refer to => [ Cylinder Head Overview ] Cylinder Head Overview.
The sealing surfaces could be damaged.
• Carefully remove sealant residue from cylinder head and cylinder block.
• Make sure that no long scrapes or scratches result.
Risk of damaging cylinder block.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Risk of cylinder head seal leaking.
• Carefully remove all grinding and sanding residue.
• Only unpack new cylinder head gasket immediately prior to installation.
• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves.
• If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.
Risk of damaging valves and piston heads after working on valvetrain.
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace the bolts which are being tightened with an additional turn.
• Replace sealing rings, seals and self-locking nuts.
• Note different sealant for cylinder head sealing surfaces and bolts.
• Secure all hose connections with hose clamps appropriate for the model, refer to the electronic parts catalog ETKA.
• The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.
- Set cylinder head gasket in place.
• Pay attention to centering pins in cylinder block - arrows -.
• Cylinder head gasket installed position: the part number must be readable from the intake side.
When rotating the crankshaft, make sure the timing chain cannot damage any other components.
- If the crankshaft was turned in the meanwhile: bring the piston for cylinder 1 to TDC and then turn the crankshaft back just a little.
- Position the cylinder head.
• In order to be able to turn the cylinder head bolts, the intake camshaft must be turned with a wrench.
- Install the bolts - 1 through 8 -.
- Tighten the cylinder bolts in sequence - 1 through 8 - in 3 steps=> [ (Item 6) Cylinder Head Bolt ] Cylinder Head Overview.
- Tighten the bolts - arrows - in two steps => [ (Item 4) Bolt ] Cylinder Head Overview.
• There is no requirement to tighten the cylinder head bolts after repairs.
- Turn the vibration damper to "TDC" - arrow - using the (T10355).
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
• The marked links of the camshaft timing chain must be positioned on the markings on the chain sprockets.
- Turn the intake camshaft in direction of - arrow - with the wrench and install the camshaft timing chain. The markings on the camshaft timing chain and on the cylinder head - arrows - must line up with the markings on the chain sprockets - 1 -.
- Mount the bearing bracket and the bolts - arrows - hand-tight.
- Remove the (T40011).
- Tighten the bolts - arrows -. Refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
- Install the control valve => [ (Item 6) Control Valve ] Camshaft Timing Chain Overview.
- Install the (T40196) as illustrated.
- Turn the crankshaft 4 complete turns in the direction of engine rotation.
- Remove the (T40196).
- Install the bolts - 1 and 2 -.
- Tighten the cylinder bolts in sequence - 1 and 2 - in 3 steps. Refer to => [ (Item 6) Cylinder Head Bolt ] Cylinder Head Overview.
Further assembly is performed in the reverse order of removal, thereby observing the following:
- Change engine oil.
- Install timing chain upper cover. Refer to => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.
- Install the catalytic converter. Refer to => [ Catalytic Converter ] Service and Repair.
- Install the front muffler. Refer to => [ Front Muffler ] Front Muffler.
- Install the tower brace.
- Install air filter housing.
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.