Removal And Installation

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.
- There are a number of versions of the variable valve timing unit. Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied.

Removal

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 the connector on the cylinder block.
- the oil return line. Seal the opening in the cylinder block
- 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 nozzle pipes.
- 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.
- Detach the wiring from the injectors.
- 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.
- Separate the quick release connector for the fuel line.
- Carefully put the fuel rail to one side.

Removing Ignition Coils







- Mark up the ignition coils so that their 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.

Removing Intake Manifold

Remove:







- The EVAP hose from the intake manifold.
- the by-pass valve vacuum hose. Disconnect the connector for the electronic throttle module (ETM).
- the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws. Lift up the intake manifold. Remove the pipe screw for the water heated crankcase ventilation underneath the intake manifold.
- the pipe screw for the crankcase ventilation from the underside of the intake manifold.

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.

Remove the auxiliaries belt.

Remove:







- 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.

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).

NOTE: Use paper or similar to catch the oil that runs out.

- the center screw in the variable valve timing unit (TX55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Remove tool 999 5452.

Removing Components From Turbocharger (TC)

Remove:







- the heat deflector plate above the manifold.
- the upper engine coolant pipe. Place it to one side.
- 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 coolant pump intake pipe to the engine block a few turns. Leave the screw in place.
- 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.

NOTE: Ensure that the screw in the spark plug well is fully tightened. Variable valve timing solenoid.

- the variable valve timing solenoids.
- 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 backwards.
- 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 some help and lift of the cylinder head. Place the cylinder head on two wooden blocks.

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.

Remove the thermostat housing and transfer it to the new cylinder head.

NOTE: Do not damage the mating surfaces.

Installation

NOTE: Ensure that there is no exhaust leakage.

Cleaning

WARNING: Use a fume hood or extractor when using gasket solvent.

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.

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 as shown in the above figure. Use protractor 951 2050.

Installing Valve Lifters And Camshafts
- Lubricate the valve lifter wells.

NOTE: If the cylinder head has been replaced, the valve clearance must be adjusted.







- Install all valve lifters.
- Lubricate the camshaft bearing positions.
- 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 2 press tools 999 5454.
- Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tool.
- Install all the screws. Tighten the 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.
- 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.

Tighten the screw for securing the coolant pump inlet pipe to the cylinder block.

Installing The Manifold And Turbocharger (TC)

Install:







- new gaskets. Lift and install the manifold and turbocharger (TC).
- the nuts and washers holding the manifold to the cylinder head.
- the upper and lower turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose.
- the pipe screws for the coolant pipes. Use new seal washers. Tighten.
- 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. Install the heat deflector plate over the manifold.

Installing The Rear Camshaft Seal

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

NOTE: When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

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.
- 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

NOTE: The purpose of the procedure, "Installing the VVT unit/timing gear pulley", described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

- 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. Tighten slightly.
- 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.

NOTE: Do not turn counter clockwise during this procedure.

- Check that the timing gear pulley is still in its limit position at the oval holes.
- Tighten the center screw in the variable valve timing unit.
- Check that the variable valve timing unit does not rotate when tightening
- Install the center plug. Tighten.







Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond.

Installing The Variable Valve Timing (VVT) Unit On The Intake Camshaft
- Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit.
- Press the variable valve timing unit/timing gear onto the camshaft.
- Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.







- Turn the variable valve timing unit counter-clockwise as far as it will go.
- Slacken off the center screw.
- 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 2 cogs before the marking on the upper timing cover.

NOTE: Do not turn counter clockwise during this procedure.

- Check that the timing gear pulley is still in the limit position in the oval holes.
- Tighten the center screw in the variable valve timing unit.
- Check that the variable valve timing unit does not rotate when tightening.
- Install and tighten the center plug.







Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond. Remove the upper timing belt cover.

Installing The Timing Belt







Tighten the center screw on the belt tensioner. Tighten to 5 Nm.

Install The Belt In The Following Order:
1. Crankshaft
2. Idler pulley
3. Intake camshaft
4. Exhaust camshaft
5. Water pump
6. Belt tensioner

Install the upper belt guard.

The variable valve timing units do not have a return spring and are easily dislodged when reinstalling the timing belt. Check that the markings correspond.

NOTE: Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.

Tighten The Timing Belt







This adjustment is always carried out on a cold engine. A suitable temperature is approximately 20 degree C / 68 degree 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 above figure shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Tighten The Timing Belt







Hold the center screw secure and turn the belt tensioner eccentric counterclockwise until the tensioner indicator passes the marked position.

Tighten the screws on the exhaust camshaft timing gear pulley. Tighten to 10 Nm.

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 25 Nm.

Check that the indicator is in the correct position.

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







Press the timing belt to check that the indicator on the tensioner moves easily.

Install the upper timing belt cover.

Turn the crankshaft two revolutions. Check that the markings on the crankshaft and camshaft timing gear pulley align.

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.
- the lower engine stabilizer brace bracket in the cylinder head.
- the upper engine stabilizer brace.

Install:







- the 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 air flow (MAF) sensor. Use a clamp on the wiring at the front of the air cleaner (ACL).

Installing Intake Manifold
Clean the intake manifold gasket face to the cylinder head.

Install a new gasket on the cylinder head. Secure with the two 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 to the electronic throttle module (ETM).
- 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.
- the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten.
- the clamp between the oil pressure pipe and the oil return line. Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC).
- the lower screw for the heat deflector plate over the turbocharger (TC).
- 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.

Install:







- 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-hand engine stabilizer brace mounting.
- the battery negative 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.