Cylinder Head Gasket, Replacement
Cylinder head gasket, replacement
Removing the cylinder head gasket
Drain the coolant and loosen the front exhaust pipe
- Remove the cable from the battery negative terminal. First read Battery, disconnecting Battery Disconnecting.
- Remove the cap on the expansion tank.
- Remove the splash guard under the engine.
- Place a container under the engine's drain valve and drain the coolant.
- Move the container to the radiator's drain valve and drain any remaining coolant.
- Close the nipples.
- Remove the nuts for the manifold/front exhaust pipe.
Drain the fuel line
The illustration does not match completely since the power steering fluid tank now has another placement.
- Depressurize the fuel system according to: Fuel system pressure release Fuel System Pressure Release.
- Disconnect the fuel line quick-release connector at the engine
Note! Protect the openings against impurities in a suitable way. Make sure that all cleanliness conditions for working with the fuel injection system are followed.
- Put the line to the side.
- Detach the EVAP line at the quick-release connector.
Removing components
The illustration shows a turbo engine.
Remove:
- the exhaust manifold.
- the cover over the ignition coils.
- the ignition coils.
Mark up and lay them aside without unplugging the connectors.
- the top and front timing belt casing.
- the engine cooling fan.
Loosen screw for clamp at throttle housing (ETM-unit) so that the charge-air pipe is not bent.
Press back the charge-air pipe and lift up the cooling fan with fan shroud.
- the inlet pipe.
- screw for the inner timing belt casing.
Set the engine according to the marking
The illustration shows a turbo engine with VVT.
Markings are the same for both aspiration and turbo engines.
- Remove the right front wheel.
- Remove the nut from the cover in the fender liner.
- Install the upper camshaft belt cover.
- Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
Note! Turbo engine with VVT: Turn the crankshaft another 1/4 turn clockwise and then back counter-clockwise until the markings match. This is to ensure that VVT-unit's belt pulley is in its end-position. The markings are illustrated.
- Remove the upper camshaft belt cover.
Removing the timing belt
Slacken off the belt tensioner
- Slacken off the center screw for the belt tensioner slightly.
- Hold and fixate the centre screw, turn the tensioner's eccentric clockwise using an Allen key, width 6 mm, to 10 o'clock.
- Remove the camshaft belt from the tension roller, camshaft pulley, and idler roller.
Remove parts at the engine's trailing edge
Remove
- air filter housing with hoses.
- camshaft sensor with trigger wheel.
- torque arm with bracket.
- the spark plugs.
Note! Make sure that no impurities can fall down in the combustion compartment.
Remove timing gear pulley with variable valve timing unit. Applies to turbo engines.
- Install camshaft adjustment tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the rear of the camshafts.
First screw in the part of the tool intended for the exhaust camshaft.
Then carefully turn the exhaust camshaft clockwise with the tool until the intake camshaft tool can be installed.
- Screw the camshaft adjustment tools together.
- Remove the plug at the front edge of the variable valve timing unit (TORX 55).
- Remove the centre screw in the VVT-unit (TORX 55).
- Carefully pull out the timing gear pulley with the VVT unit.
- Timing gear pulley without VVT:
Remove the screws and remove the timing belt pulley
Remove the timing belt pulleys. Applies to aspiration engine.
- Mark up the timing belt pulleys.
Inlet and exhaust, respectively.
- Install camshaft adjustment tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the rear of the camshafts.
Note! The following applies to turbo engines: First screw in the part of the tool intended for the exhaust camshaft. Then carefully turn the exhaust camshaft clockwise with the tool until the intake camshaft tool can be installed.
- Remove the screws.
- Remove timing belt pulleys.
Loosen the camshaft cover
Install:
- tool 999 5454 PRESS TOOL 999 5454 Press Tool with 2-3 mm clearance to the camshaft cover.
Note! Make sure that the screws in the spark plug wells are tightened all the way in.
Remove
- all screws that hold the camshaft cover.
- the camshaft cover with pliers 999 5670 Pliers 999 5670 Pliers by the snap-in lugs.
Start with cylinder 1 and work alternately backward.
- wing nuts approx. 2 turns.
Repeat the procedure with the pliers.
Remove the tools.
Remove the camshaft cover.
Mark up and remove the camshafts.
Remove the cylinder head
- Remove the coolant pipe's both screws.
- Loosen the cylinder head's screws, from the outside and in.
As shown.
- Remove the cylinder head.
- Remove the cylinder head gasket.
Installing cylinder head gasket
Clean the gasket surfaces
Clean:
- exhaust connections on manifold/cylinder head.
- engine block's gasket face.
- coolant pipe's gasket face.
- gasket face between the cylinder head's top and bottom half.
Note! Use a soft putty knife and gasket solvent, if needed, part no.: 116 1440. A metal scraper may not be used. A fume hood or extractor must be used when using gasket solvent. The surfaces must be completely clean.
Secure the crankshaft position
Install the adjustment tool
- Applies to turbo engines: Pull forward the charge-air pipe.
- Remove the starter motor's mounting screws, 3 pcs.
- Place the starter motor to one side.
- Remove the blind cover plug and the sealing washer.
- Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.
- Install adjustment tool 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool.
Make sure that it bottoms out against the engine block.
- Turn the crankshaft counter-clockwise until it stops against the drift.
Note! Check that the marking on the crankshaft's timing belt pulley matches the marking on the oil pump.
Change cylinder head gasket
Install:
- a new cylinder head gasket.
- the cylinder head.
Oil in and tighten the bolts in three steps according to sequence.
See illustration.
Work from the middle and outward:
- 1. Tighten to: 20 Nm .
- 2. Tighten to: 60 Nm .
- 3. Angle-tighten 130° .
Use angle gauge 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
- Install the coolant pipe with a new gasket.
- Install new O-rings around the spark plug sockets.
Apply liquid gasket
Roll on gasket compound:
- Apply liquid gasket, part no.: 116 1059 , on the camshaft cover.
Use roller 951 1205 951 1205 Tool.
Make sure that gasket compound does not end up in the oil channels.
A thin layer is enough to seal.
- Oil in the bearing positions for the camshafts in the camshaft cover.
- Install the camshafts.
Check the markings.
- Fixate the camshafts at the front with holders 999 5453 HOLDER 999 5453 Holder and at the trailing edge with tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
Install the camshaft cover
- Install the camshaft cover.
- Tighten down the camshaft cover against the cylinder head with press tool 999 5454 PRESS TOOL 999 5454 Press Tool , 2 pcs.
As shown.
- Torque the camshaft cover's screws.
Start from the inside and work outwards.
Tighten to 17 Nm .
- Remove the tools 999 5453 HOLDER 999 5453 Holder and 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
- Install the spark plugs.
- Install the ignition coils.
Install the front camshaft seal.
Applies to turbo engine:
- Oil in and install the camshaft seal.
- For camshafts with VVT, use drift 999 5718 Drift 999 5718 Drift.
- For camshafts without VVT, use drift 999 5719 Drift 999 5719 Drift.
Applies to aspiration engine:
- Oil in and install the camshaft seals.
Use drift 999 5719 Drift 999 5719 Drift.
Install timing belt pulley with VVT-unit. Applies to turbo engines.
- Push on the timing belt pulley with the VVT-unit on the exhaust camshaft.
Note! Also check that the markings match.
- Fit the top timing belt casing to see that the markings match.
- Tighten the centre screw with 120 Nm .
- Tighten the centre plug with 35 Nm .
- Loosen the screws securing the timing belt pulley in the VVT-unit.
- Install the timing belt pulley on the inlet camshaft with two screws, but do not tighten.
Install the timing belt pulley. Applies to aspiration engine.
- Install the timing belt pulleys with two screws so that they just touch the pulleys.
Install timing belt.
- Tighten the centre screw on the timing belt tensioner with 5 Nm .
Note! Applies to cars with turbo engine:
- Turn the variable valve timing unit clockwise to the stop.
As shown.
Hold the variable valve timing unit secure in the limit position.
Install timing belt
Install the timing belt in the following order:
- crankshaft.
- the idler pulley.
- intake cam pulley.
- exhaust cam pulley.
- water pump.
- belt tensioner.
Note! Adjust the timing belt pulleys so that the screws do not end up in an end-position in the oval holes.
Tighten the timing belt
Tighten the timing belt
Note! This adjustment is done on cold engine. A suitable temperature is approximately 20 °C/68 °F. At a higher temperature, for example, with a warm engine or a higher ambient temperature, the needle is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Tension the timing belt as follows:
Fix the belt tensioner centre screw in position and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position and reaches its end-position.
Tighten the 3 screws on the timing gear pulley for the exhaust camshaft. Tighten to 10 Nm .
Tighten the 3 screws on the inlet camshaft's belt pulley with 20 Nm .
Note! The variable valve timing unit must not be released from the end-position until after the timing belt pulleys have been tightened.
Then turn the eccentric back so that the indicator reaches the marked position in the centre of the window
Secure the eccentric and tighten the center screw to 20 Nm .
Check that the indicator is in the correct position.
If not, a new adjustment must be done.
Remove:
- the camshaft adjustment tools
- crankshaft stop.
Install the plug with a sealing washer and tighten to 40 Nm.
Check
- Press the belt to check that the indicator on the tensioner moves easily.
- Install the upper timing belt cover.
- Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond.
- Check that the indicator on the belt tensioner is within the marked position.
Install the rear camshaft seal.
- Oil in the seals.
- Press in the seals with drift: 999 5450 PUNCH 999 5450 Punch.
Note! Normally a seal is placed in the same plane as the internal bevel's edge. If there are wear grooves on the shaft, the seal can be pressed in another 2 mm by reversing the tool's sleeve.
Installing components
The figure does not match exactly since the air pump has been discontinued.
Install:
- the trigger wheel
Tighten to 17 Nm .
- the camshaft position (CMP) sensor housing and a new cover.
Tighten to 17 Nm .
- the torque rod bracket.
Tighten to 50 Nm .
- the engine stabilizer brace.
Tighten to 35 Nm and angle tighten 90° .
Use angle gauge 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
- the cover over the ignition coils.
Tighten to 8 Nm .
- air filter cover with inlet hose.
Note! Applies to cars with turbo engine:
- Install charge-air pipe over the engine.
Remove seals.
- Install the solenoid valves on the air filter cover.
Installing components
Install:
- the front timing belt cover
Tighten to 12 Nm. .
- the upper timing belt cover
Tighten to 8 Nm .
- the auxiliaries belt
- the starter motor.
Tighten to 40 Nm .
Note! Applies to cars with turbo engine:
- Hose for charge-air.
Remove seals.
- relay bracket and electric cooling fan with fan shroud.
Tighten the clamp by the throttle housing (ETM-module).
- EVAP-valve, relays, connectors.
- air channels and any brake vacuum hose.
Install and fill
The figure shows the engine compartment for a car with turbo engine.
The figure does not match exactly since the air pump has been discontinued.
Check the oil level and fill oil to correct level.
Do not overfill.
Fill the cooling system.
Connect the battery's minus cable. Battery, disconnecting Battery Disconnecting
Warm up the engine until the thermostat opens and top up with coolant as needed.
Check sealing.
Checking the engine
Test drive the car to check the function of the engine.
- Wipe the engine compartment clean.
- Wipe clean steering wheel and gear lever,
- Do a final check for leakage.