Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Ignition Coil Puller (T40039)

Removing

• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

CAUTION!
Observe procedures for disconnecting battery.

- With ignition switched off, disconnect Battery Ground (GND) wire.

- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Bring the lock carrier into service position. Refer to => [ Lock Carrier, Moving into Service Position ] Lock Carrier, Moving Into Service Position.

- Remove upper coolant pipe. Refer to => [ Upper Coolant Pipe ] Upper Coolant Pipe.

- Remove intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Remove toothed belt from camshaft. Refer to => [ Toothed Belt, Removing from Camshaft Sprocket ] Toothed Belt, Removing From Camshaft Sprocket.

- Disconnect connector - 3 - on the Evaporative Emission Canister Purge Regulator Valve and the connector - 5 - on the Mass Air Flow Sensor.





- Disconnect the hoses - 1 -, - 4 -, - 6 -, - 7 -.

- Remove the air filter housing by removing the expanding clip - 2 -.

- Remove the crankcase housing ventilation pipe - 2 -.





- Remove crankcase ventilation hose on the cylinder head cover.

- Remove the pipe - 1 - on the combination valve for secondary air injection on the cylinder head cover and on the heat shield - 3 -.

- Move the pipe to the side.

- Remove heat shield.

- Remove oil supply line bolts - 1 - and - 2 -.





- Remove turbocharger bolts - 3 -.

- Disconnect electrical harness connector - arrow - from Camshaft Adjustment Valve 1 (N205).





- Disconnect electrical harness connector - arrow - at engine coolant temperature sensor.





- Remove the vacuum hose - arrow - to Secondary Air Injection (AIR) combi-valve.





- Remove coolant flange while removing the bolts - 2 - and - 3 -.

- Remove oil supply line bracket - 1 -.

• To improve clarity, the removed engine is shown from the rear.

- Unclip and free up all electrical wires on the cylinder head.

- Remove the rear coolant hose for the heat changer on the cylinder head while releasing the retaining clip on the connection flange.

- Remove Ground (GND) wire - 2 -.





- Disconnect the electrical connectors - 3 - and free up the electrical wires.

- Remove ignition coils - 1 -.

• Use the Ignition Coil Puller (T40039) to remove the ignition coils.





- Remove nuts - arrows - and remove the cylinder head cover.





- Remove both oil deflectors.

- Remove the cylinder head bolts in sequence - 1through10 -.

Head Removal Sequence:

- Remove cylinder head with a second technician.

Installing

• Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked.

• Replace cylinder head bolts.

• During assembly, replace self-locking nuts and bolts.

• Always replace bolts that are tightened to torque as well as O-rings and gaskets.

• Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.

• Carefully remove all grinding and sanding residue.

• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

• When installing a replacement cylinder head with camshafts installed, oil contact surfaces between valve lifters and cam running surfaces after installing cylinder head.

• The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head.

• Only unpack new cylinder head gasket immediately prior to installation.

• Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage.

• When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

• Secure all hose connections using hose clamps appropriate for the model type.

• During installation, all cable ties must be re-installed at the same location.

- Move the piston to TDC - top arrow - before mounting the cylinder head.





- Make sure the piston is at TDC - bottom arrow -, turn the crankshaft using the bolt for the toothed belt pulley.

- Loosen the turbocharger bracket bolts - 1 - and - 2 - approximately 2 turn to prevent tension when installing the cylinder head.





- Position cylinder head gasket.





• Pay attention to centering pins in cylinder block - arrows -.

• Observe cylinder head seal location, identification: Part number must be visible from intake side

- Install cylinder head.

- Insert cylinder head bolts and tighten by hand.

- Tighten cylinder head bolts in 3 stages in the tightening sequence shown as follows:

1.8L Cyl. Head Sequence:

• There is no requirement to retighten the cylinder head bolts after repairs.

The rest of the installation is in reverse order of removal, note the following:

- Attach the turbocharger with a new gasket to the exhaust manifold and tighten the bracket securely to the cylinder block. Refer to => [ Turbocharger Component Overview ] Turbocharger Component Overview.

- Install cylinder head cover. Refer to => [ Cylinder Head Cover ] Service and Repair.

- Install toothed belt (adjust valve timing) => [ Mount the toothed belt. ] Toothed Belt, Removing From Camshaft Sprocket.

- Install vibration damper. Refer to => [ Vibration Damper ] Vibration Damper.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Install intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Install upper coolant pipe. Refer to => [ Upper Coolant Pipe ] Upper Coolant Pipe.

- Install the front exhaust pipe with the catalytic converter. Refer to => [ Catalytic Converter with Front Exhaust Pipe ] Catalytic Converter With Front Exhaust Pipe.

- Align exhaust system free of tension. Refer to => [ Exhaust System, Aligning ] Procedures.

- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support





- Place the torque support stop on the rubber buffer and tighten the nuts - arrows -.

- Install front bumper cover.

- Connect battery. Required steps. Refer to => Starting and Charging Starting and Charging

- Check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.

• Do an oil change if the oil is dirty.

- Replace coolant => [ Filling ] Procedures.

- Check headlamp adjustment.

Tightening Specifications





* Replace bolts.

* Coat the thread and head contact surfaces with hot bolt paste.