Part 1
Cylinder head/gasket, replacement
Special tools:
999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
999 5454 PRESS TOOL 999 5454 Press Tool
999 5670 Pliers 999 5670 Pliers
999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
951 2767 Roller 951 2767 Roller
999 5450 PUNCH 999 5450 Punch
999 5718 Drift 999 5718 Drift
999 5719 Drift 999 5719 Drift
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.
Removal
Preparation
Remove:
- the radiator breather tube from the expansion tank. Install lock grip pliers
- the battery negative lead. First read Battery, disconnecting Battery Disconnecting
- 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 later leakage.
Draining the fuel system
Lower the vehicle.
Drain the fuel system according to: Fuel system pressure release.
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 charge-air pipe over the engine. Seal the openings
- cover over the injector lines
- the upper belt protective cover
- the cover over the ignition coils
Remove:
- the intake pipe between the air cleaner (ACL) and the front cover plate
- the hose clamp for the mass air flow sensor. Disconnect the connector for the mass air flow sensor
- the air cleaner housing assembly, unhook the control valve from the air cleaner housing
- fresh air hose between air filter and turbo. Disconnect the hoses from bracket at the cylinder head's trailing edge. Remove the bracket
- 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.
Remove:
- the clamp for the positive lead at the rear of the cylinder head
- upper and lower torque bracket on the cylinder head
- the pipe screw for the water-heated crankcase ventilation.
Removing the fuel rail
Remove the clamp for the injector lines at the cylinder head's trailing edge.
Unplug the connectors for the injector valves and the fuel pressure sensor as well as the water temperature sensor.
Remove the fuel rail's attaching screws according to: Fuel line, lock Service and Repair.
Spray universal oil or similar around the injector connectors on the intake manifold
Gently work the fuel rail and injectors loose.
Separate the fuel line quick-release connector.
Note! Collect any fuel spill.
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 with 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 overflow valve's 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
Lift up and remove the intake manifold.
Note! Make sure 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! Make sure that oil does not leak from the breather hole in the filler cap.
Remove:
- front timing gear casing. Pry off the auxiliaries belt
- 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
Install the upper belt protective cover.
Remove the nuts from the cover on the wing liner.
Turn the crankshaft clockwise until the markings on the crankshaft and camshafts match.
Remove the upper timing cover.
Removing the timing belt
Slacken off the centre 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 camshafts' timing gear pulley
- the screw that holds the inner timing cover to the cylinder head.
Removing the timing gear pulley
Install adjustment tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the rear of the camshafts. Screw the adjustment tool sections together into one.
Remove:
- the center plugs for the variable valve timing units
Note! Oil may drain from the VVT-units, use paper or similar to wipe up any oil
- VVT-units' centre screws. Carefully pull out the belt pulley with the VVT-unit. Remove tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
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
- inner heat deflector plate
- the nuts and washers holding the manifold to the cylinder head.
Hint: Use rust oil or similar for easier removal of the nuts.
Lift off the turbocharger and manifold. Carefully put them on top of the transmission.
Releasing the coolant pump inlet pipe
Remove:
- the screw that holds the coolant pump's intake pipe to the engine block a few turns and 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 at cylinder 1 and 5. Install tool 999 5454 PRESS TOOL 999 5454 Press Tool (2 pcs.) with 2-3 mm clearance to the camshaft cover.
Note! Make sure that the screw in the spark plug thread is tightened all the way down
- VVT solenoids
- The screws holding the camshaft cover to the cylinder head.
Use pliers 999 5670 Pliers 999 5670 Pliers 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.
Remove:
- tools 999 5454 PRESS TOOL 999 5454 Press Tool
- 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.
Note! Pay attention so that the contact faces are not damaged.
Get some help and lift of the cylinder head. Place the cylinder head on two wooden blocks.
When replacing/machining 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! Pay attention so that the contact faces are not damaged.
Installation
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.
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 mounting screws for the starter motor and pull loose the starter motor and place it to one side.
- the blind cover plug.
Turn the crankshaft slightly clockwise.
Install crankshaft stop 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool. 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 to 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.
Get help and install the cylinder head.
Lubricate and install all the screws (use new screws).
Tighten the screws as illustrated. Tighten. See Tightening torque Tightening Torque. Use protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Installing valve lifters and camshafts
Lubricate the valve lifter wells.
Note! If the cylinder head has been replaced, the valve clearance must be adjusted. See Valve clearance Adjustments.
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 Roller 951 2767 Roller. The surface must be covered without any excess.
Note! Make sure that no liquid gasket gets in to the oil channels.
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 PRESS TOOL 999 5454 Press Tool (2x).
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools
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. See Tightening torque Tightening Torque
- the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.
- the coolant pump intake pipe to the cylinder head. Use a new gasket.
Note! Apply thread sealant, 116 056 to the screw threads.
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)
- washers and nuts that hold the manifold to the cylinder head and tighten according to Tightening torque Tightening Torque
- turbo's upper and lower coolant pipes according to Tightening torque Tightening Torque
- union screws for the coolant pipes (use new sealing washers). Tighten according to Tightening torque Tightening Torque
- the oil pressure pipe
- the union screw that holds the oil pressure pipe to the turbocharger (use new sealing washers). Do not tighten!
- inner heat deflector plate.
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.
Cleaning
Use emery cloth 951 1024 to clean the shaft journal and mating surface.
Note! Clean in the direction around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other impurities are completely removed before the new seal ring is installed.
Installing the rear camshaft seal
Use drift 999 5450 PUNCH 999 5450 Punch.
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 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool 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.