Without AVS, Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Ignition Coil Puller (T40039)
• Assembly Tool (T10352) and Assembly Tool (T10352/1)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• 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 engine cover - arrows -.
- Remove the bolts - arrows - and air guide.
- Remove both the lower air guide and the air guide hose.
- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).
- Remove the air guide hose - 2 -.
- Remove the bolt - 4 - and the air filter housing.
• Ignore - 3 -.
- 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 the catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converters and Front Muffler ] Service and Repair.
- Remove the right front wheel.
- Remove the noise insulation.
- Remove the right noise insulation - arrows -.
- Remove the frame for the noise insulation.
- 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 -.
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the air guide pipe.
- 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 line 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 -.
- Disconnect the hose for the crankcase ventilation - 1 -.
- Remove the bolts - arrows - and remove the crankcase ventilation.
- 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 line.
• 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 -.
- Disconnect the connectors on the ignition coils and free up the wiring harness.
- Remove the ignition coils with the (T40039).
- 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 Evaporative Emission (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 line 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 EVAP canister - B arrow -, remove it upward - A arrow - and lay it aside.
- Disconnect the coolant hoses - arrows - and move them to the side.
- Disconnect the connector from the camshaft adjustment valve 1 (N205) - 1 -.
- Remove the bolts - arrows - and then the camshaft adjustment valve 1.
- Remove the bolts - 1 through 5 - and the timing chain guard upper section.
The control valve has a left thread.
- Remove the control valve using the (T10352) or (T10352/1) in direction of - arrow - depending on the version.
- Remove the bolts - arrows - and remove the bearing bracket.
- Rotate the vibration damper using the (T10355) into the "TDC" position - arrow -.
• The notch on the vibration damper must line up with the arrow marking on the camshaft timing chain lower cover.
- Mark the camshaft timing chain and the cylinder head - arrows - to match the marking on the chain sprockets - 1 - with a waterproof marker.
- Remove the plug - arrow -.
- Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner direction of - arrow 1 -.
- Turn the crankshaft opposite the engine direction of rotation - arrow direction 2 - and secure it with a (T40011).
• The intake camshaft switches in the engine direction of rotation.
- Remove the bolt - 1 - and guide the tensioning rail - 2 - downward.
- Remove the upper guide track - 3 - by unlocking the latch with a screwdriver and pushing the guide track forward.
- Remove camshaft timing chain from chain sprockets.
Risk of damaging valves and piston crowns.
• If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.
- Turn the sealing plug - arrows - counterclockwise 90° in the direction of the - arrow - and remove it.
- Remove the ball heads - 1 through 2 -.
- Remove the cap.
- Remove the bolts - arrows -.
- Remove the cylinder head bolts in sequence - 1 to 5 -.
• To remove the cylinder head bolts, turn the camshaft with a wrench if necessary.
• Make sure all wires and cables are disconnected!
• 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 ] Cylinder Head Overview.
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 the cylinder head seal silicone layer and recessed area from being damaged, always handle seal with extreme care.
Risk of damaging open valves.
• 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 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 camshaft housing.
• 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.
- Set cylinder head in place.
- Insert cylinder head bolts and tighten by hand.
• In order to be able to turn the cylinder head bolts, the intake camshaft must be turned with a wrench.
- Cylinder head tightening sequence, refer to => [ Cylinder Head Tightening Sequence ] Cylinder Head Overview:
• There is no requirement to tighten the cylinder head bolts after repairs.
- Rotate the vibration damper using the (T10355) into the "TDC" position - arrow -.
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
• The marked links of the camshaft timing chain must be positioned on the markings on the chain sprockets.
- Turn the intake camshaft in direction of - arrow - with the wrench and install the camshaft timing chain. The markings on the camshaft timing chain and on the cylinder head - arrows - must line up with the markings on the chain sprockets - 1 -.
- Mount the bearing bracket and the bolts - arrows - hand-tight.
- Remove the (T40011).
- Tighten the bolts - arrows -. Refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
- Install the control valve => [ (Item 6) Control Valve ] Camshaft Timing Chain Overview.
Further installation is performed in the reverse order of removal, thereby observing the following:
- 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.