Remove

CYLINDER HEAD REMOVAL
Removing Vanos Control Unit
- Unscrew oil pipe at VANOS control unit.

Installation Note: Check seals, replacing them is necessary. Torque to 50 ±5 Nm (37 ±3 lb ft).




- Unscrew suspension eye.

Installation Note: Check for ground strap (1).




- Unscrew pulse sender.




- Remove wiring duct for pulse sender.




- Remove Thermostat Housing Cover
If applicable, unscrew thermostat housing for other work on cylinder head later.




Installation Note: Sealing surfaces must be clean and without oil.
Check rubber profile gasket, replacing it if necessary.




Installation Note: Check installed direction. Vent or arrow faces up. Replace seal.




Remove Cylinder Head Cover
- If applicable, pull plugs off of ignition coils.




- Unscrew nuts.
- Remove ignition coils.

Installation Note: Check for ground strap of ignition coils at cylinder 3 and 6.




- Unscrew cylinder head cover.




NOTE: Cylinder head cover is separated from the cylinder head as far as transmission of oscillation is concerned by employing rubber mounts and gaskets.

- Check arrangement of cover installation.
1 Cover nut
2 Washer
3 Rubber mount




Installation Note: Check cover gasket, replacing it if necessary. Place outer and inner cover gaskets on cylinder head in advance.




Installation Note: Check for correct seating of gasket on back of the cylinder head when mounting the cylinder head cover.

Installation Note: Install and align cover.

- Screw on cover nuts, but do not tighten them.
- Tighten cover nuts diagonally from inside to outside. Torque bolts to: 6 mm 10 Nm (7 ft lb) 7 mm 15 Nm (11 ft lb).




- Take off plastic cover.
- Lift out lock and remove plastic cover for the intake camshaft.




- Turn engine in its direction of rotation until the peaks of cams on intake and exhaust camshafts for cylinder no. 1 point to each other.




- Hold crankshaft in TDC using Special Tool 11 2 300.

CAUTION: Remove special tool before operating the engine.




- Hold camshafts using Special Tool 11 3 240.




- Screw plugs out of control unit.




- Unscrew bolts of sprocket on the exhaust camshaft.




- Press down on upper chain tensioner and lock using Special Tool 11 3 290.




- Unscrew nuts.
- Remove VANOS control unit.




Installation Note: Check for dowel sleeves (1). Apply 3 Bond 1209** liquid sealing compound at the corners of the joint between the cylinder head and VANOS control unit. Replace gasket.




- Unscrew nuts of intake camshaft.




- Remove thrust washer.




- Remove sprockets together with chain.




NOTE: If applicable, for work on the cylinder head later.
- unscrew thrust washer bolts.
- Remove thrust washer.




- Remove sender gear.

Installation Note: Tightening torque.

Sprocket To Camshaft Flange
7mm [1]
Step #1 5 Nm (3.5 ft lb)
Step #2 22 Nm (16 ft lb).

6mm [1] 10 Nm (7 ft lb).

Splined Shaft To Intake Camshaft
14X1.5 [1]
Step #1 40 Nm (30 ft lb)
Step #2 Torque Angle 60°.

[1] Screw size.





- Unscrew secondary tensioner.




- Unscrew chain guide.




- Unscrew chain tensioner.

Caution: Spring pressure.




Installation Note: Align groove in piston perpendicular to the tensioning rail. Replace gasket.




Arrangement of Parts:
1 - Sleeve
2 - Spring
3 - Piston




- Press upper chain tensioner down and arrest by inserting Special Tool 11 3 290.
- Unscrew sprockets.
- Lift both sprockets off complete with chain.




- Unscrew console for upper chain tensioner.




- Lift sprocket off together with chain.




CAUTION: Prevent chain from slipping down with a piece of wire.




Unscrewing Cylinder Head
- Unscrew timing case cover from cylinder head.




- Unscrew cylinder head bolts in several steps from outside to inside using Special Tool 11 2 250.
- Lift cylinder head off.




NOTE: Some of the washers are locked in the standard cylinder heads to prevent them from being lost.