Removing and Installing Cylinder Head

REMOVING AND INSTALLING CYLINDER HEAD


Removing

The cylinder head can be taken off without removing the engine.

1. Disconnect battery ground wire.

2. Unscrew cap on coolant expansion tank.

3. Remove splash guard.

4. Unscrew coolant drain plug on radiator and drain coolant.





5. Remove poly-rib belt.

6. Remove drive belt cover.

7. Turn engine to TDC in cylinder no.1.









8. Remove distributor cap, unscrew distributor rotor and remove protective cap.





9. Remove mount for distributor cap.

10. Relax belt tension and pull camshaft belt off of camshaft sprocket.

11. Unscrew 2 mounting bolts on rear drive belt cover.

Rear Drive Belt Cover Mounting Bolts:

12. Unscrew fuel lines.





13. Remove plastic cover on fuel collection tube, pull off wire plugs on fuel injectors and lay wire harness aside.

14. Unscrew aluminum plugs, coolant line and bolts (with attached washers) and remove camshaft housing from cylinder head.

Note: Make sure that hydraulic valve tappets do not fall out and are not mixed up.





15. Remove air cleaner assembly.

16. Unscrew bolt of intake brace.





17. Remove intake distributor by dismantling holder on oil dipstick tube. hose on brake booster, hose on intake distributor, retaining clamp on accelerator cable and mounting bolts of intake distributor/cylinder head.





18. Unscrew bolts of exhaust manifold/catalytic converter pipe flange.

Exhaust Flange:

19. Unscrew hose clamp on heater regulating valve and two screws on neck for coolant circuit.

20. Unscrew mounting nuts for cylinder head.

Note: Order for unscrewing mounting nuts is crosswise from outside to inside.

21. Take off cylinder head.


Installing

1. Install cylinder head gasket in correct position.





2. Mount cylinder head.





Tightening order: see figure.

Note: Never use a lubricant for installation of cylinder head nuts and washers. Only give the threads of studs a light coat of engine oil. The washers must not turn when tightening cylinder head nuts! If necessary, check this with paint stripes. In the repair Sector the washers can be reused after roughening the bearing surface for the cylinder head with a rough sandpaper.

A. Preloading Cylinder Head Gasket
1st step 20 Nm
2nd step 50 Nm
3rd step 90 Nm

3. Mount camshaft housing.
Tightening torque for socket head bolts: 20 Nm.
Tightening torque for aluminum plugs: 40 Nm.

4. Install timing belt, Service and Repair

5. Adjust polyrib belt, Adjustments