Cylinder Head
Cylinder Head
Special tools, testers and auxiliary items required
• Locking pin (T40069)
• Camshaft locator (T40070)
Removing
• The following removal and installation procedure is for the left cylinder head. The procedure for the other side is identical.
CAUTION!
Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to => [ Before Opening High Pressure Fuel Injection System ] Before Opening High Pressure Fuel Injection System. Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.
- Remove front engine cover - arrows -.
- Remove bolts - arrows -.
- Remove air duct - 1 - and - 2 -.
- Drain coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
- Remove both front wheels.
- Remove front bumper cover.
- Bring lock carrier into service position. Refer to =>
Radiator Support Radiator Support
- Remove upper section of intake manifold.
- Disconnect fuel line - arrow -.
- Remove low pressure line, thereby removing bolts and union nuts - 1 through 6 -.
- Remove intake manifold lower section.
- Disconnect electrical harness connectors at fuel injectors.
- Remove ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt
- Remove front coolant pipe. Refer to => [ Front Coolant Line ] Front Coolant Line.
Left cylinder head:
- Remove power steering pump.
- Remove oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.
Right cylinder head:
- Disconnect vacuum hose - 1 - at vacuum pump.
• Ignore - arrows -.
Continued for both sides:
- Remove nut - 2 - of relevant threaded fastener for front exhaust pipe/exhaust manifold, which is accessible from top.
• To improve clarity, the removed engine is shown from the rear.
- Remove heat shield - arrows - for left drive axle.
Right cylinder head and vehicles with automatic transmission:
- Unbolt right drive axle from transmission flange shaft.
Continued for both sides:
- Separate exhaust system at relevant clamping sleeve - arrows - and push clamping sleeve toward the rear.
- Remove nuts - 1 - and - 3 - of relevant threaded fastener for front exhaust pipe/exhaust manifold, which are accessible from bottom.
• To improve clarity, the removed engine is shown.
- Disconnect front exhaust pipe from exhaust manifold.
- Disconnect electrical harness connector - 1 - for oxygen sensor before catalytic converter on the relevant side and free up the wiring.
• Ignore - 2 -.
Left cylinder head:
- Separate electrical connector - 2 -.
• Ignore - 1 - and - arrows -.
- Remove bolt - arrow - and pull oil dipstick guide tube upward and out.
All:
- Remove cylinder head cover. Refer to Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Remove left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.
- Remove camshaft timing chains from camshafts. Refer to => [ Camshaft Timing Chains ] Camshaft Timing Chains.
- Remove bolts - arrows - at rear of cylinder head.
• Left cylinder head: 3 bolts.
• Right cylinder head: 4 bolts.
- Follow sequence - 1 to 8 - when loosening cylinder head bolts.
- Carefully remove cylinder head.
Installing
• Replace cylinder head bolts.
• During assembly, replace self-locking nuts and bolts.
• Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings.
• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
• Carefully remove all grinding and sanding residue.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
• Checking cylinder head for distortion => [ Checking cylinder head for distortion ] Cylinder Head Assembly Overview
• Only unpack new cylinder head gasket immediately prior to installation.
• Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage.
• Install cylinder head gasket onto guide sleeves. Marking "oben " (top) or part number must face toward cylinder head.
• After installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller cam followers and cam lubricating surfaces after installing cylinder head.
• Do not remove plastic bases protecting free up valves until immediately before installing cylinder head.
• When replacing cylinder head or cylinder head seal, coolant and engine oil must be changed.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be re-installed at the same location.
• After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.
- Before installing the cylinder head, set the crankshaft and camshafts to the TDC setting by mounting the camshaft locating tool ( T40070) on both cylinder heads and tightening it to 20 Nm.
• The camshaft locating tool (T40070) is correctly positioned when the holes for the cylinder head bolts remain free.
• Crankshaft holder (T40069) must be screwed into crankshaft - 1 -.
- Position cylinder head gasket.
• Pay close attention to alignment pins - arrows - in cylinder block.
• Pay attention to installation position of cylinder head gasket, marking " oben" (top) or part number must face toward cylinder head.
- Install cylinder head.
- Insert new cylinder head bolts and tighten by hand.
- Tighten cylinder head in sequence indicated, in 3 stages as follows:
- Using torque wrench, tighten to 40 Nm.
- With a rigid wrench, 90° (1/4 turn) additional turn.
- With a rigid wrench, 90° (1/4 turn) additional turn.
• There is no requirement to retighten the cylinder head bolts.
- Tighten bolts - arrows - to 9 Nm.
• Left cylinder head: 3 bolts.
• Right cylinder head: 4 bolts.
Further installation is in reverse order of removal, noting the following:
- Install camshaft timing chains. Refer to => [ Installing ] Camshaft Timing Chains.
- Install left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.
- Install cylinder head cover. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install front exhaust pipe with catalytic converter. Refer to: Left, Vehicles with manual transmission => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe With Catalytic Converter, Vehicles with automatic transmission => [ Left Front Exhaust Pipe with Catalytic Converter, Automatic Transmission ] Left Front Exhaust Pipe With Catalytic Converter, Automatic Transmission; Right, Vehicles with manual transmission => [ Right Front Exhaust Pipe with Catalytic Converter ] Right Front Exhaust Pipe With Catalytic Converter, Vehicles with automatic transmission => [ Right Front Exhaust Pipe with Catalytic Converter ] Right Front Exhaust Pipe With Catalytic Converter.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install right drive axle.
- Install oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.
- Install power steering pump.
- Install front coolant pipe. Refer to => [ Front Coolant Line ] Front Coolant Line.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install intake manifold lower-section with high and low-pressure lines.
- Install intake manifold upper-section.
- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support
- Install front bumper cover.
- Change engine oil.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
- Fill power-steering system oil and bleed steering system.
Tightening Specifications
