Rear Cylinder Head

1. Drape the wing protectors over the wings and remove the engine cover.
2. Disconnect the negative cable from the battery.
3. Open the cap on the expansion tank and release the pressure.
4. Raise the car.





5. Remove the lower spoiler sections.
6. Drain the coolant from the radiator.





7. Insert two Wedges, part no. 83 95 238, between the oil sump and subframe and between the gearbox and subframe.
8. Lower the car.





9. Remove the mass air flow sensor with hose.
10. Detach the power steering hose from the holder.
11. Remove the right-hand engine attachment with bracket and engine mount.





12. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
13. Release the multigroove belt from tension.
14. Remove the coolant pump pulley and power steering pump pulley.
15. Remove the belt tensioner and generator air intake.
16. Remove the timing cover.





17. Unhook the throttle cable.
18. Remove the vacuum hoses and unplug the pressure sensor's connector from the upper intake manifold.
19. Detach the vacuum hose and the two water hoses from the throttle. Remove the turbo pressure hose with charge air bypass pipe.
20. Unplug the throttle's connector and detach the venting valve hose from the underside of the throttle.





21. Detach the fuel lines.
22. Undo the upper intake manifold and move it aside. Unplug the connectors from the ignition discharge module and injector.





23. Remove the middle intake manifold.
24. Remove the lower intake manifold. Plug the holes with paper or the like.
25. Undo the coolant bridge and move it aside. Mind the gaskets
26. Remove the crankshaft pulley.





27. Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use Installation tool for camshaft scrod KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft.





28. Undo the tensioning pulley and adjusting rollers. Use tool 83 94 983 as a counterstay on the adjusting rollers.
29. Mark the direction of rotation on the belt. The belt can also be marked with the respective camshaft markings and crankshaft marking to facilitate refitting. Remove tool KM-800-10 from the crankshaft. Let locking tools KM-800-1 and KM-800-2 remain. Remove the lower adjusting roller. Ensure the washer behind the roller is also removed. Remove the timing belt.





30. Remove the bracket with tensioning roller and the upper adjuster roller.





31. Remove the ignition discharge module.
32. Remove the camshaft cover. Make sure that the O-rings are in place and that they do not fall into the engine.





33. Rotate the crankshaft to 60° BTDC. Note the marking.
34. Remove the camshaft sprockets.
35. Remove the coolant pump.
36. Remove the inner timing cover.

WARNING: The jaws of the open-ended spanner used as a counterstay when removing the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.





37. Detach the front exhaust pipe from the rear exhaust manifold.





38. Undo and remove the exhaust camshaft. Undo the bolts in stages, 1/2 to 1 turn at a time. Note the marking on the bearing cap
It is important to finish removal at the bearing cap where the tappets are under load.
Remove the stuffing box.

NOTE: The intake camshaft need not be removed.

39. Remove the tappets using magnetic tool 83 91 401. Arrange the tappets in the Valve rack part no. 83 93 787.
40. Undo the cylinder head bolts in the order shown. First slacken them a 1/4 turn and then 1/2 a turn. Remove the cylinder head. Be careful when putting it down as the intake camshaft is still in place and the valve stems could be bent accidentally.