Cylinder Head and/or Gasket Replacement
Cylinder head / gasket, replacing
Special tools: 999 5452, 999 5454, 999 5670, 999 5451, 951 2050, 951 2767, 999 5450, 999 5718, 999 5719
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Removing the cylinder head gasket
Preparation
Remove
- the radiator breather tube from the expansion tank. Install lock grip pliers
- the battery negative lead.
- the right front wheel.
Draining coolant
Raise the car.
Remove the splash guard under the engine.
Open the engine nipple.
Drain the coolant into a container.
Close the nipple.
Removing components
Remove
- the clamp between the oil pressure pipe and the oil return line at the turbocharger (TC)
- the pipe screw that holds the oil pressure pipe to its connector on the cylinder block
- the oil return line. Seal the opening in the cylinder block
- the screws and spacers at the exhaust manifold support bracket
- the lower screw that holds the heat deflector plate over the turbocharger (TC)
- the nuts for the front exhaust pipe connection to the turbocharger (TC).
Lift off the exhaust pipe and tie it up. Seal the opening in the exhaust pipe.
Note! The metal hose for the front exhaust pipe is easy to damage if it is twisted. Handle the exhaust hose with care to avoid leakage later.
Draining the fuel line
Lower the car.
Drain the fuel line.
Removing components
Remove
- the engine stabilizer brace between the suspension turrets
- the ground strips between the engine and the firewall
- the heat deflector plate above the turbocharger (TC)
- the plastic charge air pipe above the engine. Seal the openings
- the cover over the ignition coils
- the upper engine coolant hose for the engine and radiator
- the screw holding the dip stick pipe to the intake manifold
- the brake vacuum hose from the intake manifold.
Undo the clamp holding the plastic charge air pipe to the electronic throttle module.
Remove
- the connector from the mass air flow (MAF) sensor
- the intake hose from the mass air flow (MAF) sensor. Seal the opening.
Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket.
Remove
- the clamp for the positive lead at the rear of the cylinder head
- the torque bracket
- the pipe screw for the water-heated crankcase ventilation.
Removing the fuel rail
Remove the clamp for the injector wiring at the rear of the cylinder head.
Separate the fuel line quick-release connector.
Remove the fuel rail mounting screws.
Spray universal oil or similar around the injector connectors on the intake manifold.
Gently work the fuel rail and injectors loose.
Carefully put the fuel rail to one side.
Removing ignition coils
Mark up the ignition coils so that the original positions can be established.
Remove the mounting screws for the ignition coils and the screws at the two ground terminals.
Disconnect the connector for the variable valve timing solenoid.
Lift up and place the ignition coils and wiring to one side.
Remove
- the crankcase ventilation hose from the top of the camshaft cover
- the camshaft position sensor (CMP) housing and trigger wheel
- the cover at the rear of the intake camshaft.
Removing the intake manifold
Remove
- the EVAP hose from the intake manifold
- the by-pass valve vacuum hose
- the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws
- the pipe screw for the crankcase ventilation from the underside of the intake manifold.
Disconnect the connector for the electronic throttle module.
Lift up and remove the intake manifold.
Note! Ensure that the fuel pressure pipe is not damaged.
Removing components
Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.
Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.
Note! Ensure that oil does not leak from the ventilation hole in the filler cap.
Take off the auxiliaries belt.
Remove
- the front timing cover
- the hose for the water-heated crankcase ventilation from the thermostat housing.
Separate the connector for the engine coolant temperature (ECT) sensor.
Setting up the engine
Remove the nuts from the cover on the fender liner.
Position the upper timing cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.
Remove the upper timing cover.
Removing the timing belt
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.
Remove
- the timing belt from the timing gear pulley
- the screw that holds the inner timing cover to the cylinder head.
Install tool 999 5452 at the rear of the camshafts.
Removing the timing gear pulley
Remove the cable duct from its mountings on the right-hand suspension turret.
Note! Do not damage the paintwork.
Hold the cable duct out of the way and remove
- the plug at the front of the variable valve timing unit (TX55)
- the center screw in the variable valve timing unit (TX55).
Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.
Timing gear pulleys without variable valve timing units:
Remove screws and remove the timing gear pulley.
Remove tool 999 5452 .
Removing components from turbocharger (TC)
Remove
- the upper coolant pipe with the hose
- the heat deflector plate above the manifold
- the oil pressure pipe for the turbocharger (TC)
- the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side
- the nuts and washers holding the manifold to the cylinder head.
Lift off the turbocharger and manifold. Carefully put them on top of the transmission.
Releasing the inlet pipe for the coolant pump
Remove
- the screw that holds the inlet pipe for the coolant pump on the cylinder block
- the two screws for the connection between the coolant pipe and the bypass channel.
Carefully turn the pipe to remove it from the cylinder block.
Removing the camshaft cover and cylinder head
Remove the spark plugs from cylinders 1 and 5.
Install 2 tools 999 5454 . Leave a 2-3 mm gap to the camshaft cover.
Ensure that the screw in the spark plug well is fully tightened. Variable valve timing solenoid.
Remove all the screws securing the camshaft cover to the cylinder head.
Use pliers 999 5670 to lift the cover from the cylinder head.
Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward.
Slacken off the wing nuts approximately 2 turns. Repeat the procedure.
Carefully press out the front and rear camshaft seals.
Remove
- tools 999 5454
- the camshaft cover
- the camshafts
- the screws holding the cylinder head onto the cylinder block.
Start at the sides and work alternately towards the center.
Get help to lift off the cylinder head.
Note! Do not damage the mating surfaces.
When replacing or working on the cylinder head
Lift out the valve lifters. Use a magnet or suction cup.
Note! Keep the valve lifters in a container filled with oil to stop them draining.
Remove the thermostat housing.
Note! Do not damage the mating surfaces.
Cleaning
Clean the gasket faces for
- the manifold. Check that the studs are tightened
- the coolant bypass channel
- the thermostat housing
- the intake manifold
- the cylinder block
- camshaft cover.
Blow the oil ducts clean.
Note! Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.
Warning! Use a fume hood or extractor when using gasket solvent!
Installing the cylinder head gasket
Tightening torque
For tightening torques not in the text, see Tightening torque
Setting up the engine
Position the crankshaft
Remove the starter motor mounting screws. Pull out the starter motor and place it to one side.
Remove the blind cover plug.
Turn the crankshaft slightly clockwise.
Install crankshaft stop 999 5451 . Ensure that it bottoms out against the cylinder block.
Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing the cylinder head
Ensure that all studs at the exhaust ports are tightened.
Lubricate the studs with paste 116 1408.
Install a new cylinder head gasket.
Install the cylinder head.
Lubricate and install all the screws. Use new screws.
Tighten the screws in the order illustrated
Tighten the screws in the following order:
1. 20 Nm
2. 60 Nm
3. Angle-tighten 130° Use protractor 951 2050.
Installing valve lifters and camshafts
Lubricate the valve guide wells.
Install all the valve lifters.
Lubricate the camshaft bearing seats.
Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line.
Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line
Applying liquid gasket
Install new O-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 1161 059 to the camshaft cover.
Use roller 951 2767 . The surface must be completely covered without any excess.
Note! Ensure that no liquid gasket gets in to the oil ducts.
Installing the camshaft cover
Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
Install the camshaft cover.
Install press tool 999 5454 (2x).
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.
Install the intake manifold and lifting eyes, tighten screws from the middle and outwards.
Remove the press tools.
Install:
- the variable valve timing (VVT) solenoid. Use a new gasket
- the spark plugs. Tighten to 30 Nm
- the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.
Connect the connector for the engine coolant temperature (ECT) sensor.
Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.
Note! Apply thread sealant, P/N 116 056, to the screw.
Install the screw for mounting the coolant pump inlet pipe to the cylinder block.
Installing the manifold and turbocharger (TC)
Install:
- new gaskets.
Lift and install the manifold and turbo.
- the nuts and washers holding the manifold to the cylinder head
- the heat deflector plate above the manifold
- the upper turbocharger (TC) coolant pipe. Tighten the clamp on the rubber hose
- the pipe screws for the coolant pipes. Use new seal washers. Tighten to 26 Nm
- the oil pressure pipe
- the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. Do not tighten!
Lubricate the studs on the turbocharger (TC). Use paste 116 1408.
Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten!
Installing the rear camshaft seal
Use drift 999 5450.
Lubricate the surface of the seal that the camshaft rotates against.
Press in the seal until the drift bottoms out.
Note! If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.
Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.
Installing the front camshaft seals
Use drift 999 5718 at the camshaft with the variable valve timing (VVT) unit.
Use drift 999 5719 at the camshaft without the variable valve timing (VVT) unit.
Lubricate the surface of the seal that the camshaft rotates against.
Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.
Remove the drift.
Install the screw holding the inner timing cover to the cylinder head.
Installing the timing gear pulley
Timing gear pulleys with variable valve timing units
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit and timing gear on to the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Do not tighten!
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.
Check that the timing gear pulley is still in its limit position at the oval holes.
Tighten the center screw for the variable valve timing unit to 120 Nm.
Check that the variable valve timing unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm.
Timing gear pulleys without variable valve timing units
Install the timing gear pulley on the camshaft with 2 screws. Do not tighten!
Check that the markings on the timing gear pulley and the upper timing cover correspond.
Installing the timing belt
Tighten the center screw on the belt tensioner. Tighten to 5 Nm.
Turn the variable valve timing unit clockwise to the stop.
Hold it secure in the limit position.
Install the belt in the following order:
1. Crankshaft
2. Idler pulley
3. Intake camshaft
4. Exhaust camshaft
5. Water pump
6. Belt tensioner
Note! Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes. Ensure that the markings correspond.
Tighten the timing belt
This adjustment is always carried out on a cold engine. A suitable temperature is approximately 20°C / 68°F
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Hold the center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
Tighten the three screws on the exhaust camshaft timing gear pulley to 10 Nm.
Install the screw missing on the intake timing belt pulley.
Tighten the screws to 20 Nm.
Note! The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.
Hold the eccentric secure and tighten the center screw. Tighten to 20 Nm.
Remove:
- camshaft adjustment tool 999 5451
- crankshaft stop 999 5452 . Install the plug with a new sealing washer. Tighten to 40 Nm.
Checking the markings and belt tension
Check
Press the timing belt to check that the indicator on the tensioner moves easily.
Turn the crankshaft two turns. Check that the markings on the crankshaft pulley and timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.
Check that the indicator on the belt tensioner is within the marked position.
Remove the upper timing cover.
Installing components
Install:
- front timing cover
- the cable duct to the mountings on the right suspension turret
- the auxiliaries belt
- the expansion tank
- the servo oil reservoir
- the bleed hose to the expansion tank. Tighten the clamp.
Check that the hoses are correctly positioned.
Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.
Install
- the starter motor
- the pipe screw for the water-heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm
- the camshaft position sensor (CMP) housing and trigger wheel
- a new cover at the rear of the intake camshaft
- the upper engine stabilizer brace.
Install
- bracket and lifting eyelet for the engine stabilizer brace bracket
- the ignition coils and ground terminals according to earlier markings.
Connect the connector for the variable valve timing solenoid.
- the clamp for the positive lead at the lifting eyelet bracket
- the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp.
Connect the connector to the mass airflow (MAF). Clamp the wiring at the front of the air cleaner (ACL).
Installing the intake manifold
Clean the intake manifold gasket face to the cylinder head.
Install a new gasket on the cylinder head. Secure with the three screws in the lower row.
Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.
Note! Take care not to damage the fuel pressure pipe.
Route the crankcase ventilation hose through the cavity in the intake manifold.
Install
- the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm
- the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm
- the hose to the canister purge (CP) valve
- the control hose for the turbocharger (TC) by-pass valve
- the brake vacuum hose
- the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
- the cover over the ignition coils
- the upper timing cover
- the upper engine coolant hose for the engine and radiator. Tighten the clamp
- the screw holding the dip stick pipe to the intake manifold.
Connect the connector for the electronic throttle module.
- the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.
Installing the fuel rail
Install
- the fuel rail. Use new screws.
Press the quick-release connector for the fuel pressure line until it clicks.
- the clamp for the injector wiring at the rear of the cylinder head
- the protective cover over the injector connectors
- the charge air pipe over the engine. Tighten the pipe using the three screws on the engine. Tighten the clamps.
Installing components
Raise the car. Install
- the pipe screw that holds the turbocharger (TC) oil pressure pipe to the engine. Use new seal washers. Tighten to 38 Nm
- the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten to 12 Nm
- the clamp between the oil pressure pipe and the oil return line
- the screws and spacers at the manifold support bracket and cylinder block.
Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC). Tighten to 30 Nm.
- the splash guard under the engine
- the plastic nuts for the hatch in the right fender liner
- the right front wheel.
Lower the car
Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. Tighten to 26 Nm.
Install
- the heat deflector plate above the turbocharger (TC)
- the ground strips between the cylinder head and the firewall
- the engine stabilizer brace between the suspension turrets.
Clamp the servo hose at the right engine stabilizer brace mounting
- the battery negative lead. First read Note when disconnecting/connecting the battery lead .
Check
Replace the oil and oil filter if necessary.
Check
- the engine oil level
- the servo oil level
- the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks.
Top up the coolant if necessary.