Removing the Cylinder Head
1. Fit the wing cover and remove the battery cover and the battery negative cable.2. Remove the cap to the expansion tank.
3. Unplug the connectors for the heated oxygen sensors and carefully guide down the cables.
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Figure 1
4. Remove the heat shield over the turbo.
5. Detach the turbo oil delivery pipe.
Figure 2
6. Remove the nuts for the catalytic converter connection to the turbo.
7. Raise the car and remove the right-hand front wheel and the right-hand wing liner.
Figure 3
8. Remove the lower spoiler shield. Detach the hose to the headlight washer and unplug and remove the connector.
CV: Remove the chassis reinforcement, front subframe.
Figure 4
9. Position a container under the car, connect a hose to the radiator and drain the coolant.
Figure 5
10. Remove the lower turbocharger delivery pipe.
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Figure 6
11. Detach the catalytic converter mounting from the cylinder block.
12. Use protective safety glasses. Position a container under the car, connect a hose and open the cock on the coolant pump and drain the remaining coolant.
Figure 7
13. Close the cock.
Tightening torque 20 Nm (15 lbf ft)
14. Detach the turbo coolant pipe.
15. Remove the stay between the exhaust manifold and the cylinder block.
16. Remove the oil return pipe from the turbo.
17. Remove the stay between the intake manifold and the cylinder block.
Figure 8
18. Remove the starter motor positive cable.
19. Lower the car and remove the upper engine cover.
Figure 9
20. Remove the turbocharger delivery hose from the throttle body and the turbocharger delivery pipe.
21. Detach the hoses and remove the turbo intake manifold. Detach the mass air flow sensor connector. Plug the turbo inlet.
Figure 10
22. Remove the air filter housing cover and the air filter. Detach the inlet hose and remove the air filter housing.
Figure 11
23. Release any pressure in the fuel system by carefully pressing the service valve needle. Collect any fuel spill. Detach both fuel lines from the fuel rail while gripping the lower nut. Plug the fuel lines. Use 82 92 948 Plugs, A/C system, kit.
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Figure 12
24. Disconnect the quick-release coupling for the breather line and detach the fuel lines and ventilation lines from the clips on the camshaft cover. Bend up the breather hose from the intake manifold and place it on the camshaft cover.
25. Remove the cover over the ignition coils.
Figure 13
26. Unplug the ignition coil connectors. Unplug the connectors to the turbo solenoid valve and undo the cable clips.
Figure 14
27. Unplug the A/C pressure sensor connector, the connectors to the coolant temperature sensor, the engine control module, the solenoid valve for the bypass valve, the throttle body, the intake manifold pressure sensor, the atmospheric pressure sensor, the 1DM module, the oil pressure sensor and the ground cable to the engine control module.
Figure 15
28. Disconnect the hose from the turbo bypass valve and the solenoid valve.
29. Detach the cable duct and bracket from the camshaft cover. Fold aside the engine's wiring harness.
30. Remove the wiring harness nuts from the oil filter housing and the intake manifold and detach the wiring harness.
Figure 16
31. Remove the ignition coils.
Figure 17
32. Detach the crankcase ventilation hose from the camshaft cover.
33. Detach the ground cable from the camshaft cover.
34. Remove the camshaft cover.
Figure 18
35. Reset the engine to zero by turning the crankshaft clockwise until the marking on the crankshaft pulley is aligned with the marking on the timing cover. The cyl.1 cams on the intake and exhaust camshafts should be pointing up/in.
Figure 19
36. Disconnect the coolant hose from the pipe and the cylinder head.
Figure 20
37. Position a jack with a wood block under the oil sump and relieve the right-hand engine pad. Detach the right-hand engine mounting.
38. Disconnect the coolant hose from the pipe on the cylinder head. Detach the vacuum hose from the brake servo.
Figure 21
39. Cars with secondary air injection pump: Remove the pump pipe and upper retaining bolt from the intake manifold.
40. Detach the power steering pump.
41. Remove the bolt to the dipstick pipe. Detach the connector and unplug it from the pipe.
Figure 22
42. Remove the chain tensioner. Use 83 96 129 Oil filter tool B207.
Figure 23
43. Detach the camshaft pinions. Hold with a wrench on each respective camshaft flat.
44. Fit a cable tie to the exhaust camshaft pinion and chain, remove the camshaft pinions and guide down the exhaust camshaft pinion and chain.
45. Remove the plug from the cylinder head.
46. Remove the bolt to the chain guide at the intake side, move the guide away and refit the bolt.
Figure 24
47. Remove the cylinder head bolts in accordance with the sequence indicated in the illustration.