Cylinder Head, Removing

Removing Cylinder Head

Special tools and equipment





- Tensioning Bolt (Socket head fastener) T10092





- Locking Pin T40011

Note:
- Always replace the cylinder head bolts.
- When performing repairs, replace seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.
- The hose connectors and hoses of charge air system must be free of oil and grease before assembling.
- When installing an exchange cylinder head with the camshafts installed, the contact surfaces between bucket tappet and cam running surface must be oiled after installation of the cylinder head.
- The plastic protectors fitted to protect the open valves must only be removed immediately before installing the cylinder head.
- When installing a new cylinder head or cylinder head gasket, drain off all the old coolant and re-fill with new coolant.
- Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.3 mm in width, or when no more than the first 4 turns of the spark plug threads are cracked.


Procedure

Removing:

- Engine in vehicle
- Lock carrier must be in service position. Refer to Body and Frame - Radiator Support - Service and Repair - Procedures [1][2]Procedures

Note:
All cable ties which are released or cut open when removing must be located in the same position when installing.

- Observe or obtain radio code on vehicles with coded radio.
- Disconnect Ground strap at battery with ignition switched off.
- Drain coolant.
- Remove intake pipe.
- Remove ribbed belt and tensioner for ribbed belt. Refer to Drive Belts, Mounts, Brackets and Accessories - Drive Belt - Service and Repair - Procedures Service and Repair

- Remove air filter cover -arrow-.






- Disconnect connectors as follows:




1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on air mass meter
3 - on solenoid valve for charge pressure control -N75-
- Disconnect hose connections, move wiring aside and remove air filter housing -arrows-.

- Disconnect connector -arrow- from camshaft adjuster.






- Remove pipe of crankcase vent -1 -.
- Remove hose of crankcase venting from cylinder head cover.
- Remove pipe -1- from combination valve for secondary air inlet on cylinder head cover and from heat shield -3- (engine code ANB only).
- Slightly swivel secondary air inlet pipe to side.
- Remove heat shield.






- Remove bolts -1- and -2- of oil feed pipe.
- Remove bolts -3- for exhaust turbocharger.






- Disconnect connector -arrow- at coolant temperature sender -G2-/G62-.






- Disconnect vacuum hose -arrow- from combination valve.
- Remove bolts -2- and -3- and remove coolant flange.
- Remove bracket -1- for oil feed pipe.
- Unclip all wiring from cylinder head and move clear to one side.
- Remove coolant hose going to heat exchanger (heater unit) at back of cylinder head (first release retainers on connecting flange).
- Remove upper toothed belt guard.






- Set crankshaft to markings for TDC of No. 1 cylinder by turning central bolt on crankshaft sprocket in direction of rotation -arrows-.






- Attach socket head fastener T10092 into tensioner.
- Only tension pressure piston of tensioner until piston is secured with pin T4001 1.
- Remove toothed belt from camshaft sprocket.






- Disconnect Ground wire -2-.
- Disconnect connectors -3-.
- Move pipes and hoses aside.
- Remove ignition coils -1-.






- Loosen nuts -arrows- for cylinder head cover and remove cylinder head cover.
- Remove both oil deflectors.






- Loosen cylinder head bolts in correct sequence.






- Remove cylinder head.