Removing and Installing/Sealing Cylinder Head

Removing And Installing/Sealing Cylinder Head

Special Tools Required:
00 9 120 Torsion Angle Tightening Indicator

Remove both exhaust manifolds, Refer to Exhaust System.
Remove intake filter housing with air-mass flow sensor.
Remove cylinder head cover, refer to Valve Cover, Service and Repair.
Remove all spark plugs.
Remove intake air manifold, refer to Intake Manifold, Service and Repair.

Open coolant drain plug on engine block.
Drain and dispose of coolant.

Installation:
Replace sealing ring on drain plug.
Tightening torque, refer to Specifications, Mechanical.
Vent cooling system and check for leaks.

Remove coolant thermostat housing.





Remove coolant pipe.

Note:
If the coolant pipe cannot be fed out:
Release banjo bolt (1) and disconnect oil pressure line for VANOS adjustment unit.

Installation:
Replace O-ring on coolant pipe.
If necessary, replace sealing rings on banjo bolt (1).
Tightening torque of banjo bolt (1), refer to Specifications, Mechanical.

Removal
Removal of cylinder head is described separately from installation.

Remove double VANOS adjustment unit, refer to Camshaft, Lifters and Push Rods, Camshaft Engine.

Remove camshafts with bearing strips, refer to Camshaft, Lifters and Push Rods, Camshaft Engine.





Release screw connection between timing case cover and cylinder head.





Release screws, remove chain guide.





Release cylinder head bolts from outside to inside in sequence 14 to 1 Lift off cylinder head.

Installation
Installation of cylinder head is described separately from removal.

Clean sealing faces of cylinder head and engine block; if necessary, remove traces of sealing compound with hardwood spatula. Make sure no gasket remnants drop into oil and cooling channels.

There must be no oil in the tapped holes of the engine block and the timing case cover.

Danger of cracking and distorted tightening values.





Check dowel sleeves for damage and correct installation position.
Apply permanently elastic sealing compound Drei Bond 1209 to joints to timing case cover.

Replace cylinder head gasket.

Note: A 0.3 mm thick cylinder head gasket is available for cylinder heads remachined at the cylinder head gasket surface.





Put the cylinder head on.
Install new cylinder head bolts.
Apply a light coat of oil to washer contact area and thread of new cylinder head bolts.
Tighten down cylinder head bolts in sequence 1 to 14.
Tightening torque, refer to Specifications, Mechanical.

Note: Use special tool 00 9 120 for torsion angle tightening.





Install chain guide.





Insert screws and tighten down screw connection between timing case cover and cylinder head.
Install camshafts.
Install double VANOS adjustment unit.
Assemble engine.