Removal of Cylinder Head (In Car)

Cylinder Head
Removal Of Cylinder Head (in situ)






1. Allow the engine to idle. Remove fuse 19. Turn off the ignition when the engine has stopped. Refit the fuse. Lay out wing covers, remove the battery cover and the intake manifold cover, drain the coolant and disconnect the negative battery lead. Raise the car and remove the lower engine cover.






2. Lower the car slightly and remove the front right wheel and disconnect the steering servo pipe from the subframe.
3. Drive in a 83 95 238 Wedge between the oil sump and subframe on the right-hand side.
4. Remove the right-hand engine mounting with yoke and the bracket for the servo pump pipe.
5. Remove the mass air flow sensor with rubber gaiter. Unplug the connectors for the mass air flow sensor and turbo wastegate.
6. Remove the crankcase breather pipe.
7. Remove the front lifting eye from the engine and pull it out of the rubber.






8. Remove the charge air pipe, bypass valve and pressure/temperature sensor connector. Disconnect the bypass valve vacuum hose. Plug the throttle body and the hose by the charge air cooler.






9. Release the tension of the belt tensioner using 83 95 254 Drawbar handle, hydraulic belt tensioner and insert a 3.5 mm allen key into the hole. Remove the poly-V-belt.

Important: Be careful so that the belt tensioner does not break at its end position!

10. Remove the belt tensioner, detach and move aside the generator. Remove the generator bracket.






11. Unplug the temperature sensor and ignition discharge module connectors.
12. Remove the coolant hoses from the cylinder head.






13. Remove the cover from the throttle body lever. Detach the accelerator cable, remove the dipstick with pipe and detach the fuel hoses using 83 95 261 Tool, fuel hose.
14. Remove the crankcase breather nipple from the timing cover.






15. Raise the car and remove the intake manifold steady bar.






16. Remove the turbocharger steady bar.
17. Lower the car to the floor.
18. Remove the heat shield from the turbocharger and exhaust manifold.
19. Remove the four retaining nuts between the exhaust manifold and the turbocharger. Heat the nuts carefully if they are stuck.
20. Remove the servo pump and suspend it from the radiator crossmember.
21. Remove the lower screw from the steering servo pump bracket.






22. Remove the bracket for the ignition discharge module connectors from the rear lifting eye and the bracket for the heat exchanger pipe.
23. Remove the intake manifold with partition. Move the manifold rearwards towards the bulkhead. The centre retaining bolts may be more easily accessible from underneath. Leave the intake manifold in the car.






24. Remove the ignition discharge module and spark plugs.
25. Remove the camshaft cover, line up the crankshaft pulley mark with the timing cover and check that the camshafts are in line with their timing marks.






26. Undo the camshaft sprocket bolts. Hold the end of the camshaft with an open-ended spanner to prevent it from turning.
27. Undo the bolt on the idler sprocket and remove the chain tensioner. Use a 27 mm socket after removing the plug with spring and pushrod.
28. Remove the camshaft sprockets and fit a rubber band between the chain guides.
29. Remove the cylinder head. Start with the bolts in the timing cover. Proceed in reverse order to fitting. Use a pair of pliers or a magnet to retrieve the bolts.







30. Wipe up any oil that has run out. Make sure that the timing chain does not obstruct its removal and then lift off the cylinder head.