Removal of Cylinder Head
Cylinder headTo remove
1. Apply wing covers, remove the battery cover and disconnect the negative battery cable.
2. Remove the cap on the expansion tank.
3. Unplug the connector for the oxygen sensors and carefully lower the cables.
Warning: Take care as the engine can be hot
4. Remove the heat shield over the turbocharger.
5. Undo the turbocharger oil delivery pipe.
6. Remove the upper oxygen sensor.
7. Remove the nuts for the catalytic converter connection with the turbocharger.
8. Raise the car and remove the front right wheel and the right wing liner.
9. Remove the lower spoiler shield. Detach the hose to the headlamp washers, unplug the connector and remove it. CV: Remove Chassis reinforcement, front supporting frame, CV
10. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.
11. Remove the lower turbocharger pressure pipe.
12. Cut the front pipe at the silencer (87 mm from end of silencer). Use 83 95 667 Pipe cutter/exhaust system.
13. Detach the front pipe from the catalytic converter.
14. Remove the heat shield over the steering gear.
15. Remove the heat shield over the catalytic converter.
16. Remove the lower oxygen sensor.
17. Remove the catalytic converter bracket from the cylinder block and from the catalytic converter.
18. Remove the catalytic converter.
19. Place a receptacle under the car, connect a hose, open the tap on the coolant pump and drain the coolant. Move the receptacle and drain the coolant pump.
20. Fit the plug with 74 96 284 Thread locking adhesive. Use protective goggles.
Tightening torque 20 Nm (15 ft. lbs.).
21. Undo the turbocharger coolant pipe.
22. Remove the stay between the exhaust manifold and the cylinder block.
23. Remove the oil return pipe from the turbocharger.
Important: If the flexible part of the return oil pipe is bent, the resulting restriction may become permanent and cause damage to the turbo charger.
24. Remove the stay between the intake manifold and the cylinder block.
25. Disconnect the starter motor positive cable.
26. Undo the bolts on the power steering pipe clamps on the subframe.
27. Undo the rear torque arm bolts slightly.
28. Fit 83 96 152 Engine centring tool kit to the subframe. Due to narrow tolerances on the drive shafts, the centring tool must be used to carefully fit the powertrain to the subframe and body during refitting. Adjust the centring tool bolts so that the adjuster screw slots are completely visible. See Centring tool, engine and subframe.
29. Lower the car and remove the upper engine cover.
30. Remove the turbocharger delivery hose from the throttle body and the turbocharger delivery pipe.
31. Detach the hoses and remove the turbocharger inlet pipe. Unplug the mass air flow sensor connector. Plug the turbocharger inlet.
32. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing.
Warning: Removing the fuel line involves work on the car's fuel system. The following points must therefore be observed when taking any action:
^ Ensure good ventilation! If there is approved ventilation for extraction of fuel fumes then this must be used.
^ Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation of the skin.
^ Have a fire extinguisher class BE at hand! Be aware of the risk for sparks, e.g. in connection with circuit breaking, short-circuiting, etc.
^ Absolutely No Smoking!
^ Wear protective glasses.
33. 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.
34. Disconnect the quick-release coupling for the ventilation line and detach the fuel lines and ventilation lines from the clips on the camshaft cover. Bend up the ventilation hose from the intake manifold and place it on the camshaft cover.
35. Remove the cover over the ignition coils.
36. Unplug the ignition coil connectors. Unplug the connector to the turbocharger solenoid and undo the cable clips.
37. Unplug the A/C pressure sensor connector, the connector to the coolant temperature sensor, the engine control module, see Before removing a control module, bypass solenoid valve, throttle body, manifold absolute pressure sensor, barometric pressure sensor, IDM module and ground cable on the engine control module.
38. Detach the hose from the turbocharger wastegate and solenoid valve.
39. Detach the cable duct and bracket from the camshaft cover. Bend aside the engine wiring harness.
40. Remove the wiring harness nuts from the oil filter housing and inlet pipe and detach the wiring harness.
41. Remove the ignition coils.
42. Detach the crankcase ventilation hose from the camshaft cover.
43. Detach the ground lead from the camshaft cover.
44. Remove the camshaft cover.
45. Zero the engine 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.
46. Detach the coolant hose from the pipe and the cylinder head.
47. Remove the right engine mounting.
48. Detach the coolant hose from the pipe on the cylinder head and remove the IDM module. Disconnect the hose quick-release couplings from the vacuum pump.
49. Undo the power steering pump.
50. Disconnect the quick-release coupling from the EVAP canister purge valve and remove the bracket.
51. Remove the throttle body and the engine control module.
52. Unplug the injector connectors.
53. Remove the bolt of the dipstick pipe.
54. Detach the vacuum hose and the purge hose from the intake manifold.
55. Detach the vacuum hose from the fuel pressure regulator.
56. Remove the intake manifold.
57. Remove the chain tensioner. Use 83 96 129 Oil filter tool B207
58. Detach the camshaft pinions. Grip the respective camshaft flats with a spanner.
59. Fit a cable tie to the exhaust camshaft pinion and chain, remove the camshaft pinions and lower the exhaust camshaft pinion with chain.
60. Remove the plug from the cylinder head.
61. Remove the bolt for the chain guide on the intake side, move away the guide and screw in the bolt again.
62. Remove the cylinder head.