Cylinder Heads
Cylinder Heads
Special tools, testers and auxiliary items required
• Spanner Wrench (3212)
• Socket (T40058)
• Locking Pin (T40069)
• Camshaft Clamp (T40133)
Removing
• Engine installed.
• The following information describes how to remove both cylinder heads at the same time.
• If only one cylinder head will be removed, follow the applicable instructions in the following description.
There is a risk of injury because the fuel is under very high pressure.
• Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.
- Reduce fuel pressure in high pressure area.
- Remove the upper coolant pipe. Refer to => [ Upper Coolant Pipe ] Upper Coolant Pipe.
- Remove ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the lower section of the intake manifold.
- Disconnect the electrical connectors on the fuel injectors.
- Remove the left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.
- Remove the bolts - arrows - for the coolant pump ribbed belt pulley for power steering pump using a (3212) to counter hold.
- Remove the bolts - 1 and 2 - and lay the power steering pump to the side.
• Ignore - 3 - and - arrow -.
- Disconnect electrical connector - 3 - for Engine Coolant Temperature (ECT) Sensor (G62).
- Remove the bolts - 1, 2, 4 and 5 - on the front coolant pipe.
• Ignore - arrows -.
- Remove the nuts - arrows - and the high pressure line protective plate - 1 -.
- Remove the threaded connection - 2 - and move the fuel supply line to the side.
- Disconnect the connectors - 1 and 6 -.
• Ignore - 3, 4, 5 and arrows -.
- Disconnect the right and left electrical connectors - arrows - on the camshaft adjuster actuators.
- Remove the bolts - 1 and 2 - and free up the electrical wiring harness.
- Remove the cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Disconnect the electrical connector - 3 - on the Camshaft Position (CMP) sensor (G40).
- Remove the Ground (GND) wire bolt - 4 -.
• Ignore - 1, 2 and 5 -.
- Remove the bolts - arrows - and the bracket for the left connectors.
• Ignore - 1 to 4 -.
- Remove the bolts - arrows - and the bracket for the right connectors.
• Ignore - 1 to 4 -.
- Remove the bolt - arrow - and remove the oil dipstick with the guide tube.
- Open the clamp and remove the vacuum hose form the vacuum pump - arrow -.
- Free up vacuum hose.
- Remove the bolts - arrows - on the rear of the cylinder head.
• Left cylinder head: 3 bolts.
• Right cylinder head: 4 bolts.
• The cams on the intake camshaft partially restrict access to the cylinder head bolts, such as bolts - 1 and 2 - shown in this example..
• The slider on the camshaft must be pressed in the direction of - arrow A - using a plastic wedge to remove the bolt - 1 -.
• The slider on the camshaft must be pressed in the direction of - arrow B - using a plastic wedge to remove the bolt - 2 -.
Risk of damage.
• The camshaft slider must only slide in the base-circle phase, that is the rocker arm on the slider that will be moved must not be loaded with a cam. When loosening the cylinder head bolts, follow the sequence described in the following instruction.
There is a risk it could break.
• The camshaft sliders must not slide on the thin ribs.
- Insert the (T40058) guide pins as follows:
• The large diameter - arrow 1 - faces the engine.
• The small diameter - arrow 2 - faces the adapter.
- Rotate the crankshaft in the direction of engine rotation - arrow - using the (T40058) until the camshaft position shown in the following illustration is reached.
• The openings - arrows - on the exhaust camshafts must face toward the outer side of the engine as shown in the illustration.
Left Cylinder Head
- Slide the unloaded camshaft slider - B - as far as the stop in the direction of the - arrow -.
Right Cylinder Head
- Slide the unloaded camshaft slider - F - as far as the stop in the direction of the - arrow -.
Continuation for Both Cylinder Heads
- Turn the crankshaft one full revolution (360°) in the direction of engine rotation - arrow - using the (T40058).
• The threaded holes - arrows - in the camshafts must face upward.
Left Cylinder Head
- Remove the bolt - 1 -.
Right Cylinder Head
- Remove the bolt - 2 -.
Continuation for Both Cylinder Heads
- Turn the crankshaft one full revolution (360°) in the direction of engine rotation - arrow - using the (T40058).
• The openings - arrows - on the exhaust camshafts must face toward the outer side of the engine.
Left Cylinder Head
- Slide the unloaded camshaft sliders - B and C - as far as the stop in the direction of the - arrow -.
Right Cylinder Head
- Slide the unloaded camshaft slider - F - as far as the stop in the direction of the - arrow -.
Continuation for Both Cylinder Heads
- Turn the crankshaft one full revolution (360°) in the direction of engine rotation - arrow - using the (T40058).
• The threaded holes - arrows - in the camshafts must face upward.
- Remove the camshaft timing chains from the camshafts. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.
Risk of damaging valves and piston crowns.
• If the camshaft timing chain was also only removed on one cylinder head, the crankshaft must not be rotated any more.
Left Cylinder Head
- Remove the bolts - 3 through 9 - while sliding the unloaded camshaft slider - A - accordingly.
- Remove the cylinder head.
Right Cylinder Head
- Remove the bolts - 10 through 16 - while sliding the unloaded camshaft sliders - D and E - accordingly.
- Remove the cylinder head.
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 cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.
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 the 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.
• Note different sealant for cylinder head sealing surfaces and bolts.
• 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 cylinder head cover.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Parts Catalog.
• The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.
- Before installing the cylinder head, set the crankshaft and camshafts to "TDC" and install the (T40133) on both cylinder heads and tighten to 25 Nm - arrows -.
• The (T40133) is correctly positioned when the holes for the cylinder head bolts remain free.
• (T40069) must be screwed into the crankshaft.
- Set cylinder head gasket in place.
• Pay close attention to centering pins - arrows - in cylinder block.
• Cylinder head seal installation position: Identification "oben" (top) or the cylinder head part number.
- Position the cylinder head.
Left Cylinder Head
- Insert the bolts - 1 through 7 - while sliding the unloaded camshaft slider - A - accordingly.
- Tighten the bolts in 3 steps following the sequence - 1 to 7 -. Refer to => [ (Item 10) Bolt ] Cylinder Head Overview.
Right Cylinder Head
- Insert the bolts - 8 through 14 - while sliding the unloaded camshaft sliders - D and E - accordingly.
- Tighten the bolts in 3 steps following the sequence - 8 to 14 - => [ (Item 10) Bolt ] Cylinder Head Overview.
Continuation for Both Cylinder Heads
- Position the camshaft timing chain on the camshafts => [ Installing ] Camshaft Timing Chains, Removing From Camshafts.
- Remove the (T40133) and the (T40069).
- Turn the crankshaft one full revolution (360°) in the direction of engine rotation - arrow - using the (T40058).
• The openings - arrows - on the exhaust camshafts must face toward the outer side of the engine.
Left Cylinder Head
- Slide the unloaded camshaft sliders - B and C - as far as the stop in the direction of the - arrow -.
Right Cylinder Head
- Slide the unloaded camshaft slider - F - as far as the stop in the direction of the - arrow -.
Continuation for Both Cylinder Heads
- Turn the crankshaft one full revolution (360°) in the direction of engine rotation - arrow - using the (T40058).
• The threaded holes - arrows - in the camshafts must face upward.
Left Cylinder Head
- Insert the bolt - 15 - and tighten it in 3 steps => [ (Item 10) Bolt ] Cylinder Head Overview.
Right Cylinder Head
- Insert the bolt - 16 - and tighten it in 3 steps => [ (Item 10) Bolt ] Cylinder Head Overview.
Continuation for Both Cylinder Heads
- Turn the crankshaft one full revolution (360°) in the direction of engine rotation - arrow - using the (T40058).
• The openings - arrows - on the exhaust camshafts must face toward the outer side of the engine.
Left Cylinder Head
- Slide the unloaded camshaft slider - B - as far as the stop in the direction of the - arrow -.
Right Cylinder Head
- Slide the unloaded camshaft slider - F - as far as the stop in the direction of the - arrow -.
Continuation for Both Cylinder Heads
- Tighten the bolts - arrows -.
• Left cylinder head: 3 bolts.
• Right cylinder head: 4 bolts.
• Do not tighten the cylinder head bolts.
Install in reverse order of removal paying attention to the following:
- Install oil dipstick guide tube. Refer to => [ Oil Dipstick Guide Tube - Tightening Specifications ] Cylinder Head Overview.
- Position the camshaft timing chain on the camshafts => [ Installing ] Camshaft Timing Chains, Removing From Camshafts.
- Install the cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install front coolant pipe. Refer to => [ Front Coolant Pipe ] Front Coolant Pipe.
- Install power steering pump.
- Install the front muffler. Refer to => [ Front Muffler ] Front Muffler.
- Install the fuel supply line and the lower section of the intake manifold.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the upper coolant pipe. Refer to => [ Upper Coolant Pipe ] Upper Coolant Pipe.
- Change engine oil.
- Replace the coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.