Cylinder Head, Removal and Installation
Cylinder head, removing(with engine installed)
Note: All cable ties which are releas~d or cut during removal must be replaced in same position d~ling installation.
- remove toothed belt Service and Repair
Note: It is not necessary to loosen and remove vibration damper
- drain coolant at engine block on right and left (arrow)
- tightening torque: 30 Nm (22 ft lb)
- save for reuse, as necessary
- remove bolts (arrows) securing exhaust pipe at left and right
- remove supply line at fuel manifold (arrow)
- remove return line at fuel pressure regulator (arrow)
- remove bolt securing pressure regulator to fuel manifold (arrow)
Note: When installing fuel pressure regulator, first press it directly into the seat of the O-ring seal. Do not pull in with bolts.
- disconnect breather hose (arrow) at rear of intake manifold
- disconnect vacuum hose (arrow)
- remove bolt securing upper part of supporting clamp for engine wiring harness (arrow)
- remove mounting bracket for ignition wire holder (arrows)
- disconnect linkage for cruise control (top arrow)
- release throttle cable by unclipping both retaining clips (lower arrow)
- disconnect heater supply hose for coolant at rear of both cylinder heads
- release hose under engine wiring harness clamp (arrows)
- remove screws securing two.spark-plug covers
- disconnect spark-plug connectors using puller tool in direction of arrow
- remove ignition cables complete with distributor caps
- disconnect harness connector for kn6ck sensor at left and right
- disconnect air mass sensor harness connector
- disconnect connector on throttle valve harness connector potentiometer
- disconnect thermosensor
- disconnect Idle Air Control Valve harness connector
- remove Idle Air Control Valve
- remove hose from carbon canister (see arrows)
- remove air temperature sensor (arrows)
- remove wiring holder behind rear toothed belt guard at right-hand side and, if necessary, also on left-hand side
- remove bolts securing coolant hose holder on right-band cylinder head at rear (arrow)
- disconnect heater supply hose from cylinder
- disconnect harness connector for Hall sender on right-hand distributor (arrow)
If right cylinder head heeds to be removed:
- disconnect temperature sensor harness connector on right cylinder head
- remove breather hose at top
Note: Turn hose using pliers until retaining lug unlatches.
- remove breather hose on cylinder head on left-hand side at rear (arrow)
- remove bolts securing fuel rails (arrows), lift out complete with injectors and place on plenum chamber
Note: When installing, ensure that the O-rings on the injectors are not damaged. Replace 0-rings and moisten slightly with clean engine oil
- remove bolts (arrows) securing intake manifold and lift out
Note: Watch front breather hose under intake manifold.
- unscrew dipstick guide and pull out
Note: This procedure is only necessary when removing left-hand cylinder head (arrow).
- remove transmission oil filler tube bolt
- remove cylinder head cover (arrows)
Note: The two center mounting bolts are different. The bolt with the longer hexagon fitting must be installed at the rear
- remove bolts (arrows) securing cruise control vacuum unit
Note: This procedure is only necessary for removal of left-hand cylinder head
- remove bolts (arrows) securing bracket for cruise control vacuum unit
Caution! Do not forget deflector plate during installation.
- remove cylinder head bolts (arrows) in reverse sequence of tightening
- remove cylinder head
- check cylinder head for distortion
- maximum permissible distortion: 0.1 mm (0.004 inch)
Cylinder head, installing
- clean sealing surfaces
- make sure that word 'oben on cylinder head gasket faces towards cylinder head
- fit cylinder head in place
Caution! Watch centering dowels in cylinder block.
- insert cylinder head bolts hand-tight
Cylinder head, tightening
Requirement
- engine cold
- tighten cylinder head bolts in three stages in order shown in illustration
- Stage I = 40 Nm (30 ft lb)
- Stage II = 60 Nm (44 ft lb)
- Stage III = 1/2 turn
- when tightening bolts in Stage III; use a regular wrench, without stopping. Two 1/4 turns is permissible.
Note: It is not necessary to retighten the cylinder head bolts during maintenance service or after repairs
Before installing intake manifold, first attach front breather hose under intake manifold to engine.