Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Engine Bung Set (VAS 6122)
Removing
• During installation, cable ties must be installed at the same location.
• Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the (VAS 6122).
- Remove the camshafts. Refer to => [ Camshafts ] Camshafts.
Risk of damaging valves and piston crowns.
• Do not turn the crankshaft if the camshaft has been removed.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the electrical connectors - arrow - and free up the electrical wire.
• Ignore - 1 and 3 -.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.
- Open the coolant reservoir cap.
- Remove front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converters and Front Muffler ] Service and Repair.
- Remove the right front wheel.
- Remove the air guide pipe - 1 and 2 -.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Remove the bolt - 1 - and remove the air guide pipe downward.
• Ignore items - 2, 3 and 4 and the arrow -.
- Disconnect electrical connectors - 1 and 2 - and free up electrical wire - arrows -.
- Remove bolts - 1 and 2 - and remove the turbocharger support.
- Remove the banjo bolt - 2 - and move the coolant pipe to the side.
- Remove the bolts - 1 - on the oil return line.
- Remove the bolt - 3 - on the oil supply line.
• The installation location is shown with the engine removed.
- Remove the air guide pipe bolt - arrow -.
- Remove the air guide pipe; to do this, loosen the hose clamp - 1 -.
- Press the release buttons and remove the air guide hose - 2 -.
- Remove the coolant hose - 1 -.
- Remove the bolts - 2 and 3 -.
- Remove the coolant hoses - 1 and 2 -.
- Disconnect the connector - 4 - and free up the wiring harness.
- Remove the vacuum hose from the vacuum pump - 5 - and free it up.
- Remove the bolt - 3 - and the coolant pipe.
• Be careful of the ground wire - arrow - when installing.
• The installation location is shown with the engine removed.
- Remove the heat shield - arrows -.
- Disconnect the oil supply line from the turbocharger - 1 -.
- Remove the coolant hoses on the rear of the cylinder head.
- Disconnect the connectors - 1 through 4 -.
- Free up the electrical cable - 5 -.
- Disconnect the vacuum hose - 6 - leading to the EVAP filter.
- Disconnect the electrical connectors - 1 - and pull the connectors out of the retainer.
- Disconnect the connectors - 2 through 4 -.
- Remove the vacuum line - 5 -.
- Disconnect the coolant pipe from the intake manifold, when doing this, remove the bolts - arrows -.
- Remove the intake manifold bracket by removing the mounting nut - 1 - and bolt - 2 -.
- Remove the oil filter.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Risk of contamination to the fuel system.
• Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the fuel hose - 1 -.
- Release the Evaporative Emission (EVAP) canister - B arrow -, remove it upward - A arrow - and lay it aside.
- Disconnect the coolant hoses - arrows - and move them to the side.
- Remove the bolts - arrows -.
- Remove the cylinder head bolts in sequence - 1 to 10 -.
• Make sure all wires and cables are disconnect!
• Pay attention to the tension and guide tracks when lifting the cylinder head.
- Remove the cylinder head.
- Lay the cylinder head on a soft surface, such as foam.
Installing
• For the correct tightening specifications, refer to => [ Cylinder Head Overview with AVS ] Cylinder Head Overview With AVS.
The sealing surfaces could be damaged.
• Carefully remove sealant residue from 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.
• 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.
• 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 camshafts.
• The hose supports, air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Electronic Parts Catalog (ETKA).
• To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.
- Set cylinder head gasket in place.
• Pay attention to centering pins in cylinder block - arrows -.
• Observe cylinder head seal location, identification: The part number must be visible from the intake side.
When rotating the crankshaft, make sure the timing chain cannot damage any other components.
- In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.
- Position the cylinder head.
- Insert cylinder head bolts and tighten by hand.
- Cylinder head tightening sequence. Refer to => [ Cylinder Head Tightening Sequence ] Cylinder Head Overview With AVS.
• There is no requirement to tighten the cylinder head bolts after repairs.
- Rotate the vibration damper using the (T10355) into the "TDC" position - arrow -.
Further installation is performed in the reverse order of removal, thereby observing the following:
- Install the camshafts. Refer to => [ Camshafts ] Camshafts.
- Install the timing chain guard upper section. Refer to => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.
- Change engine oil.
- Replace coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
Do not use a charger as a starting aid. There is the risk that the vehicle control modules could be damaged.