Cylinder Head, Without Screwdriver Access
Cylinder Head, without Screwdriver Access
• Camshafts without screwdriver access do not have notches in the camshafts, refer to => [ Screwdriver Access ] Cylinder Head, Screwdriver Access.
Special tools, testers and auxiliary items required
• Assembly Tool (T10352)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• Lever (T40243)
• Locking Tool (T40267)
• Camshaft Clamp (T40271)
• Ignition Coil Puller (T40039)
• Engine Bung Set (VAS 6122)
• Polydrive Bit and Drive Socket (T10070)
• Drift (T40196)
• Spark Plug Removal Tool (3122 B)
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 camshafts. Refer to => [ Camshafts ] Camshafts.
Risk of damaging valves and piston crowns.
• Do not turn the crankshaft if the camshaft has been removed.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Remove the front exhaust pipe/front muffler. Refer to => [ Front Exhaust Pipe and Front Muffler ].
- Remove the plenum chamber covers - 1, 2 and 3 -.
- Disconnect the vacuum connection - 2 - from the plenum chamber bulkhead by removing the vacuum hose - 3 - on the back side - arrow -.
- Remove the coolant hoses on the back of the cylinder head.
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.
- Disconnect fuel lines - 1 and 2 -.
- Loosen the hose clamps - arrows - and remove the air guide hose.
- Disconnect the following connectors.
2 Disconnect from Knock Sensor KS) 1 (G61)
3 From the Intake Manifold Runner Control (IMRC) Valve (N316) , Fuel Pressure Sensor (G247) and the Camshaft Position (CMP) sensor (G40).
4 From the fuel injectors
5 From the throttle valve control module (J338).
6 From the Intake Air Temperature (IAT) sensor (G42).
- Disconnect the connector - 2 - and free up the wire.
- Remove the coolant line bracket - arrow -.
• The engine is not shown in the illustrations that follows.
- Remove the intake manifold bracket by removing the mounting nut - 1 - and bolt - 2 -.
- Disconnect the coolant hose - arrow -.
- Remove the bolts - 1 and 2 - and move the oil supply line to the side.
- Remove the bolt - 3 - and move the coolant pipe to the side.
- Loosen the hose clamp - arrow -, pull of the air guide hose and move it to the side.
- Disconnect the connectors - 1 and 4 - from the oil pressure switch (F22) and the reduced oil pressure switch (F378).
- Disconnect the connectors - 1 and 2 - and free up the wire.
- Remove the bolts - arrows - and then remove the turbocharger support.
- Remove the bolts - arrows - on the oil return line.
- Remove the nuts - arrows - and push the catalytic converter to the rear.
- Remove the spark plugs using a (3122 B).
- Remove the bolts - arrows -.
- Remove the cylinder head bolts with the (T10070) in the following sequence: - 1 through 10 -.
• 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
• Tightening specifications, refer to => [ Cylinder Head, without Screwdriver Access ] Cylinder Head, Without Screwdriver Access.
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 pistons when starting, carefully rotate engine at least 2 full revolutions.
• Replace the bolts which are being tightened with an additional turn.
• Replace sealing rings, seals and self-locking nuts.
• 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 camshafts.
• 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 Parts Catalog.
• To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• The engine oil and coolant must be changed if the cylinder head or cylinder head seal 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.
- Cylinder head, tightening sequence, refer to => [ Cylinder Head Tightening Sequence ] Cylinder Head Overview, Without Screwdriver Access.
• 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.
Further installation is performed in the reverse order of removal, thereby observing the following:
- Install the camshafts. Refer to => [ Camshafts ] Camshafts.
- Install the timing chain guard upper section. Refer to => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.
- Change the engine oil.
- Replace coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Install the catalytic converter.
- Install the front exhaust pipe/front muffler. Refer to => [ Front Exhaust Pipe and Front Muffler ] .
Do not use a charger as a starting aid. There is the risk that the vehicle control modules could be damaged.