Removing Cylinder Head

Cylinder head, removing

^ Engine in vehicle

Note:
• Secure all hose connections with the correct hose clips (same as original equipment)
Refer to parts supplier.
• All cable ties, which are opened or cut open when removing must be replaced in the same position when installing.

- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery Ground strap.
- Drain cooling system. Service and Repair
- Remove intake manifold. Service and Repair
- Disconnect coolant pipe from thermostat housing only.
- Unbolt coolant pipe flange from cylinder head (left) and place it to one side.
- Unplug connectors on ignition coils.
- Unclip/release all pipes and hoses on the cylinder head and move clear.




- Disconnect air hose -1- from upper air pipe.
- Unbolt retainer for oil return line -2-.




- Release hose -4- from upper air pipe (hose leads to turbocharger).
- Remove bolts -1- and -5- for heat shield on back of cylinder head.
- Remove bolts -2- and -3- for upper air pipe.
- Remove upper air pipe and heat shield.
- Unbolt turbocharger from exhaust manifold.
- Remove ribbed belt and tensioning element.
- Remove toothed belt guard (upper). Service and Repair




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




- Unscrew bolts (left arrows) and remove coolant expansion tank together with hoses.
- Unscrew bolt (right arrow) and remove power steering reservoir. Do not disconnect the hoses.




- Screw M5 x 55 stud -1- into toothed belt tensioning element.
- Screw hexagonal nut -2- onto stud -1- using large washer -3-.
- Tension pressure piston of tensioning element only until it can be secured with a locking pin (e.g. from lifting appliance 2024 A) -arrow-.

Note: If it is not possible to insert the locking pin, carefully tension the pressure piston of the tensioning element just enough to allow the toothed belt to be removed.

- Take toothed belt off camshaft sprocket.
- Unbolt ignition coils.
- Remove cylinder head cover.

Head Removal Sequence:

- Maintain sequence when loosening and tightening cylinder head bolts.
- Remove cylinder head.