Cylinder Heads
Cylinder Heads
Special tools, testers and auxiliary items required
• Spanner Wrench (3212)
• Polydrive Bit and Drive Socket (T10070)
Removing
• The following information describes how to remove both cylinder heads at the same time.
• If only one cylinder head will be removed, follow the applicable instructions in the following description.
• When installing, bring all cable ties back to the same positions.
- To remove the right cylinder head, remove the upper coolant pipe. Refer to => [ Upper Coolant Pipe ] Upper Coolant Pipe.
- Remove ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the lower section of the intake manifold.
- Remove the catalytic converter. Refer to => [ Left Catalytic Converter ] Left Catalytic Converter, => [ Right Catalytic Converter ] Right Catalytic Converter.
- Disconnect the left and right connectors - 1, 2 and 3 - from the fuel injectors.
• Ignore - 4 -.
- Remove the affected camshaft timing chain from the camshafts. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.
- Remove the (T40071) from the left cylinder head.
- Remove the bolts - 1 and 2 - and then remove the chain tensioner on the right cylinder head.
• The (T40071) remains inserted.
- Remove the bolts for the coolant pump ribbed belt pulley, using a (3212) to counter hold.
- Remove the bolts - 1 and 2 - and move the power steering pump to the side.
• Ignore - 3 - and - arrow -.
- Disconnect the Air Conditioning (A/C) compressor regulator valve (N280) - 1 - connector.
- Remove the Ground (GND) wire bolt - 2 -.
- Disconnect the connectors from the left cylinder head:
1 for Camshaft Position (CMP) Sensor 2 (G163)
3 for Camshaft Adjustment Valve 2 (N208)
- Move the electrical wiring harness to the side.
• Ignore - 2 - and - arrows -.
- Disconnect electrical connector - 1 - for Engine Coolant Temperature (ECT) Sensor (G62).
- Remove the front coolant pipe bolts - arrows -.
- Disconnect the connector - 2 -.
- Remove the GND wire bolt - 1 -.
- Disconnect the connectors from the right cylinder head:
1. Camshaft adjustment valve 1 (N205)
2. Camshaft Position (CMP) sensor (G40)
- Move the electrical wiring harness to the side.
• Ignore - arrows -.
- Remove the bolt - arrow - and remove the oil dipstick and guide tube.
- Disconnect the connectors:
1 For Heated Oxygen Sensor (HO2S) (G39) (right)
2 For Heated Oxygen Sensor (HO2S) 2 (G108) (left)
- Open the clamp - 1 - and remove the vacuum hose from the vacuum pump.
• Ignore - arrows -.
- Remove the bolts - arrows - on the rear of the cylinder head.
• Left cylinder head: 3 bolts.
• Right cylinder head: 4 bolts.
- Loosen the cylinder head bolts in the following sequence - 1 through 8 -.
- Remove the bolts, remove the cylinder head and place it on a soft surface (foam).
Installing
• For the correct 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.
• No oil or coolant must be in the cylinder head bolt blind holes 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 the valvetrain.
• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace bolts that are tightened to the specification.
• Replace self-locking nuts, sealing rings, seals and O-rings.
• For the correct seal and cylinder head bolts, refer to the Parts Catalog.
• If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory, refer to the Parts Catalog.
• Change the coolant and engine oil whenever replacing the cylinder head or cylinder head seal.
• Secure the camshafts in the Top Dead Center (TDC) position on both cylinder heads using the (T40133) - arrows - (25 Nm).
• The (T40133) is correctly positioned when the holes for the cylinder head bolts remain free.
• Secure crankshaft - 1 - in TDC position using (T40069) in TDC.
- Install the new seals on the coolant pipe.
- Set cylinder head gasket in place.
• Installed position: The marking "top" or the part number must be legible.
• Pay close attention to alignment bushings in cylinder block - arrows -.
- Set cylinder head in place.
- Tighten the cylinder head bolts. Refer to => [ Cylinder Head, Tightening Specifications and Sequence ] Cylinder Head Overview.
- Tighten the bolts - arrows - for the lower timing chain cover => [ Lower Timing Chain Cover, Tightening Specifications and Sequence ] Timing Chain Covers Overview.
• Left cylinder head: 3 bolts.
• Right cylinder head: 4 bolts.
• There is no requirement to tighten the cylinder head bolts after repairs.
Install in reverse order of removal paying attention to the following:
- Install oil dipstick guide tube. Refer to => [ Oil Dipstick Guide Tube - Tightening Specifications ] Cylinder Head Overview.
- Install front coolant pipe. Refer to => [ Front Coolant Pipe ] Front Coolant Pipe.
- Electrical connectors and wiring routing.
- Install the power steering pump.
- Install the camshaft timing chains. Refer to => [ Camshaft Timing Chains ] Camshaft Timing Chains.
- Install the catalytic converter. Refer to => [ Left Catalytic Converter ] Left Catalytic Converter, => [ Right Catalytic Converter ] Right Catalytic Converter.
- Install the lower part of the intake manifold.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the upper coolant pipe. Refer to => [ Upper Coolant Pipe ] Upper Coolant Pipe.
- Change engine oil.
- Replace coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.