Cylinder Heads

Cylinder Heads

Special tools, testers and auxiliary items required

• Spanner Wrench (3212)

• Camshaft Clamp (T40133)

• Locking Pin (T40069)

Removing

• Engine installed.

• The following information describes how to remove both cylinder heads at the same time.

• If only one cylinder head will be removed, follow the applicable instructions in the following description.

• When installing, bring all cable ties back to same positions.

There is a risk of injury because the fuel is under very high pressure.

• Reduce the fuel pressure down to residual pressure before opening the high pressure area of the fuel injection system.

- Reduce fuel pressure in high pressure area.

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

- Removing the ribbed belt:

• => [ Ribbed Belt, Vehicles with Hydraulic Power Steering ] Ribbed Belt, Vehicles With Hydraulic Power Steering

• => [ Ribbed Belt, Vehicles with Electro-Mechanical Power Steering ] Ribbed Belt, Vehicles With Electro-Mechanical Power Steering

- Remove the lower section of the intake manifold.






- Disconnect the connectors on the fuel injectors.

- Remove the affected camshaft timing chain from the camshafts. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.

Vehicles with Hydraulic Power Steering






- Remove the bolts for the coolant pump ribbed belt pulley, using a (3212) to counter hold.

- Remove the bolts - 1 and 2 - and lay the power steering pump aside.






• The illustration shows the installation location on a vehicle with dynamic steering.

• Ignore - 3 - and - arrow -.

All Vehicles






- Disconnect the connector - 3 - from the engine coolant temperature sensor (G62).

- Remove the bolts - arrows -.

- Remove the clips - 1 and 4 -, loosen the clamp - 2 - and remove the coolant hoses from the front coolant pipe.

• Ignore - 5 -.

- Remove the threaded connection - 1 - and move the fuel supply line to the side.






- Disconnect the connectors - 2 and 3 -.

- Remove the bolt - arrow - and remove the oil dipstick and guide tube.






- Open the clamp - arrow - and remove the vacuum hose from the vacuum pump.






- Remove the bolts - arrows - on the rear of the cylinder head.






• Left cylinder head: 3 bolts.

• Right cylinder head: 4 bolts.

- Loosen the cylinder head bolts in the following sequence - 1 through 8 -.






- Remove the bolts, remove the cylinder head and place it on a soft surface (foam).

Installing

Tightening specifications:

• => [ Cylinder Head - Tightening Specification and Sequence ] Cylinder Head Overview

• => [ Lower Timing Chain Cover, Tightening Specifications and Sequence ] Timing Chain Covers Overview

The sealing surfaces could be damaged.

• Carefully remove sealant residue from the cylinder head and cylinder block.

• Make sure that no long scrapes or scratches result.

Risk of damaging cylinder block.

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

Risk of cylinder head seal leaking.

• Carefully remove all grinding and sanding residue.

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

• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.

Risk of damaging open valves.

• If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.

Risk of damaging valves and piston heads after working on the valve train.

• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.

• Replace the bolts which are being tightened with an additional turn.

• Replace self-locking nuts, sealing rings, seals and O-rings.

• Note different sealant for cylinder head sealing surfaces and bolts.

• If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover.

• Secure all hose connections with hose clamps of the same type as those equipped by the factory, refer to the Parts Catalog.

• The coolant and engine oil must be changed whenever replacing the cylinder head or cylinder head seal.

• Secure the camshafts in the Top Dead Center(TDC) position on both cylinder heads using the (T40133) - arrows - (25 Nm).






• The (T40133) is correctly positioned when the holes for the cylinder head bolts remain free.

• Secure crankshaft - 1 - in TDC position using (T40069).






- Install new seals and O-rings for the front coolant pipe.






- Set cylinder head gasket in place.

• Installed position: The marking "top" or the part number must be legible.

• Pay close attention to the alignment bushings in the cylinder block - arrows -.

- Set cylinder head in place.

- Tighten the cylinder head bolts. Refer to => [ Cylinder Head - Tightening Specification and Sequence ] Cylinder Head Overview.






- Tighten the bolts - arrows - for the lower timing chain cover. Refer to => [ Lower Timing Chain Cover, Tightening Specifications and Sequence ] Timing Chain Covers Overview.






• Left cylinder head: 3 bolts.

• Right cylinder head: 4 bolts.

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

Install in reverse order of removal paying attention to the following:

- Install oil dipstick guide tube. Refer to => [ Oil Dipstick Guide Tube - Tightening Specifications ] Cylinder Head Overview.

- Install front coolant pipe. Refer to => [ Front Coolant Pipe ] Front Coolant Pipe.

- Install the power steering pump.

- Position the camshaft timing chain on the camshafts. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.

- Remove the lower section of the intake manifold.

- Installing the ribbed belt:

• => [ Ribbed Belt, Vehicles with Hydraulic Power Steering ] Ribbed Belt, Vehicles With Hydraulic Power Steering

• => [ Ribbed Belt, Vehicles with Electro-Mechanical Power Steering ] Ribbed Belt, Vehicles With Electro-Mechanical Power Steering

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

- Change the engine oil.

- Replace coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.