Cylinder Head

Cylinder head

To remove
1. Apply wing covers and remove the battery cover and the negative battery cable.
2. Open the cap on the expansion tank.
3. Unplug the oxygen sensors and carefully take down the cables.

Warning
Exercise caution as the engine can be very hot.





4. Remove the heat shield over the turbocharger.
5. Undo the turbocharger oil delivery pipe.





6. Remove the nuts for the catalytic converter connection with the turbocharger.

Important
When removing the nuts of the catalytic converter, it is important to hold the removal tool vertically against the flange. The stud and nut can easily be broken off if they are subjected to a skew loading. Use 82 92 484 Removal tool, door hinge.

7. Raise the car and remove the front right wheel and right wing liner.





8. Disconnect and bend aside one side of the lower spoiler shield. CV: Remove the front subframe chassis reinforcement.





9. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.





10. Remove the lower turbocharger pressure pipe.





11. Undo the catalytic converter bracket from the cylinder block.
12. Use protective goggles. Place a receptacle under the car, connect a hose and open the cock on the coolant pump to drain the remaining coolant.





13. Close the cock.
Tightening torque 20 Nm (15 ft. lbs.)
14. Undo the turbocharger coolant pipe.
15. Remove the stay between the exhaust manifold and the cylinder block.
16. 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 turbocharger.

17. Remove the stay between the intake manifold and the cylinder block.





18. Disconnect the starter motor positive cable.
19. Lower the car and remove the upper engine cover.





20. Remove the turbocharger delivery hose from the throttle body and the turbo delivery pipe
21. Detach the hoses and remove the turbo inlet pipe. Unplug the mass air flow sensor connector. Plug the turbo inlet.





22. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing.





Warning
The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:
^ Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short circuiting, etc.
^ Absolutely No Smoking!
^ Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.
^ Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
^ Wear protective goggles.

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 assy.





24. 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.
25. Remove the cover over the ignition coils.





26. Unplug the ignition coil connectors. Unplug the connector to the turbocharger solenoid valve and undo the cable clips.





27. Unplug the A/C pressure sensor connector, the connector to the coolant temperature sensor, the engine control module, the bypass solenoid valve, the throttle body, the intake manifold pressure sensor, the atmospheric pressure sensor, the IDM module, the oil pressure sensor and the ground cable by the engine control module.





28. Detach the hose from the turbocharger waste gate and the solenoid valve.
29. Detach the cable duct and bracket from the camshaft cover. Move away the engine wiring harness.
30. Remove wiring harness nuts from oil filter housing and intake manifold and detach the wiring harness.





31. Remove the ignition coils.





32. Detach the crankcase ventilation hose from camshaft cover.
33. Undo ground cable from camshaft cover.
34. Remove the camshaft cover.





35. Zero the engine by turning the crankshaft clockwise until the mark on the crankshaft pulley is aligned with the mark on the timing cover, cyl. 1 cam lobes on intake and exhaust camshaft must be pointing in/up.





36. Detach the coolant hose from the pipe and the cylinder head.





37. Place a jack with a wood block under the oil sump and relieve the right-hand engine pad. Remove the right-hand engine mounting.
38. Detach the coolant hose from pipe on the cylinder head. Detach the vacuum hose from the brake servo.





39. Cars with secondary air injection pump: Remove the pump's pipe and upper retaining bolt from the intake manifold.
40. Undo the power steering pump.
41. Remove the dipstick tube bolt. Unplug the connector and detach it from the pipe.





42. Remove the chain tensioner. Use 83 96 129 Oil filter tool B207





43. Undo the camshaft sprockets. Restrain the respective camshaft using a spanner on the shaft flats.
44. Tie a cable tie around the exhaust camshaft sprocket and chain, remove the camshaft sprockets and lower the exhaust camshaft sprocket with chain.
45. Remove the plug from the cylinder head.
46. Remove the bolt for the chain guide on the intake side, move away the guide and refit the bolt.
47. Remove the cylinder head in the order shown in the illustration.





To fit
1. Carefully clean the bolt holes in the cylinder block by blowing with compressed air.
2. Clean any gasket remains from the cylinder bore, cylinder head and cylinder block sealing surfaces. Check with a steel rule that the cylinder head and cylinder block are flat and the sealing surfaces are not damaged.
3. Check the marks on the pulley and timing cover to make sure the engine is zeroed.
4. Place a new gasket on the cylinder block. Raise the sprocket and pull the chain guides together in order to get the cylinder head in place.





5. Remove the exhaust camshaft and intake camshaft bearing cap no. 2. Fit EN-48368 Adjustment tool, camshaft (B207 210 hp) or EN-48366 Adjustment tool, camshaft (B207 150 - 175 hp) onto the camshafts.
Tightening torque 10 Nm (7 ft. lbs.)





6. Fit the cylinder head according to the order shown in the illustration. Insert the bolts carefully. The threads in the cylinder block can be damaged if they are dropped rapidly.
Tightening torque step 1: 30 Nm (22 ft. lbs.)
Tightening torque step 2: 150 degrees
Tightening torque step 3: 15 degrees
Tightening torque, bolts for timing section, 35 Nm (26 ft. lbs.)





7. Remove the bolt for the chain guide. Move back the guide and fit the bolt.
Tightening torque 10 Nm (7 ft. lbs.)





8. Fit the plug in the cylinder head.
Tightening torque 25 Nm (18 ft. lbs.)
9. Fit the sprocket on the exhaust camshaft and intake camshaft without tightening. Check that the engine is zeroed.
10. Fit the chain guide "zeroed". The groove on the end of the chain tensioner must be vertical when fitting. See Timing chain tensioner - fitting. Use 83 96 129 Oil filter tool B207, and chain tensioner camshaft drive

Note
Check that chain tensioner O-ring and gasket are intact. If damaged, the entire chain tensioner must be changed.

Tightening torque 75 Nm (55 ft. lbs.)
11. Tighten the camshaft sprockets. Restrain the respective camshaft using a spanner on its flats. Remove the cable tie.
Tightening torque 85 Nm + 30 degrees (63 ft. lbs. + 30 degrees)
12. Remove the camshaft adjustment tool and fit the camshaft caps.
Tightening torque 8 Nm (6 ft. lbs.)
13. Turn over the engine 2 revolutions and reset to zero so that the belt pulley and the timing cover marks are aligned. Remove bearing caps no. 2 and no. 7 and fit EN48368 Adjustment tool, camshaft (B207 210 hp) or EN-48366 Adjustment tool, camshaft (B207 150 - 175 hp) again to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps.





14. Fit the dipstick bolt. Plug in the connector and fit the connector to the tube.





15. Cars with secondary air injection pump: Fit the pump's upper retaining bolt. Fit the pipe between the pump and the valve.
16. Fit the power steering pump with new seal.
Tightening torque 22 Nm (16 ft. lbs.)





17. Connect coolant hose to the pipe on cylinder head. Attach the vacuum hose to the brake servo.
18. Fit the right-hand engine pad.
Tightening torque, bolts to body 40 Nm + 60 degrees (30 ft. lbs. + 60 degrees)
Tightening torque, bolts to bracket 70 Nm + 60 degrees (52 ft. lbs. + 60 degrees)





19. Fit the coolant hose to the pipe on the cylinder head.
20. Fit the camshaft cover with new seal.
Tightening torque 10 Nm (7 ft. lbs.)





21. Connect the ground cable to the camshaft cover.





22. Connect the crankcase ventilation hose to the camshaft cover.
23. Fit the ignition coils.
Tightening torque 8 Nm (6 ft. lbs.)
24. Fit the wiring harness to the intake manifold and the oil filter housing.





25. Fit the cable duct and bracket to the camshaft cover.





26. Connect the hose to the turbocharger waste gate and the solenoid valve.
27. Plug in the A/C pressure sensor connector, the connector to the coolant temperature sensor, the engine control module, the bypass solenoid valve, the throttle body, the intake manifold pressure sensor, the atmospheric pressure sensor, the IDM module, the oil pressure sensor and the ground cable on the engine control module.
28. Plug in the ignition coil connectors. Make sure the cable is lying correctly and does not get pinched by the cover. Plug in the connector to the turbocharger solenoid valve and fasten the cable clips.





29. Fit the cover over the ignition coils.





30. Press the fuel lines and breather lines into the clips on the camshaft cover. Connect the quick release coupling for the breather line.





31. Connect both fuel lines to the fuel rail while restraining the lower nut. Use new seals.
Tightening torque 10 Nm (7 ft. lbs.)
32. Fit the air cleaner casing and connect the intake hose. Fit the air cleaner.





Important
To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.

33. Connect the air filter housing cover. Plug in the mass air flow sensor connector and fit the turbo inlet pipe. Attach the hoses to the turbo inlet pipe.





34. Fit the turbocharger delivery hose to the throttle body and the turbo delivery pipe.





35. Connect the starter motor positive cable.





36. Fit the stay between the intake manifold and the cylinder block.
Tightening torque 22 Nm (16 ft. lbs.)
37. Fit the oil return pipe to the turbo. Use a new gasket and new O-ring.
Tightening torque 15 Nm (11 ft. lbs.)





38. Fit the stay between the exhaust manifold and the cylinder block.
Tightening torque 22 Nm (16 ft. lbs.)
39. Fit the turbo coolant pipe with new seals.
Tightening torque 40 Nm (30 ft. lbs.).
40. Lower the car and fit the catalytic converter with new nuts so that it is butt against the turbo. Use 30 20 971 Screw-thread paste on the studs.
Tightening torque 25 Nm (18 ft. lbs.)





41. Raise the car and tighten the catalytic converter bracket bolts.
Tightening torque 25 Nm (18 ft. lbs.)
42. Fit the lower turbocharger pressure pipe.





43. Fit the lower spoiler shield. CV: Fit the front subframe chassis reinforcement.





44. Lower the car somewhat and fit the right wing liner and the front right wheel.





45. Fit the turbo oil pressure pipe. Use new seals and grip the pipe to prevent it twisting.
Tightening torque 22 Nm (16 ft. lbs.)





46. Plug in the oxygen sensor connectors.





47. Fit the heat shield over the turbocharger.
48. Connect battery negative cable and battery cover.





49. Check the oil level and top up as necessary.
50. Fill with coolant to approx. 20 mm above the mark on the expansion tank.





51. Remove the wing covers and restore car electrical functions, see After disconnecting the battery.
52. Fit the upper engine cover.