Assembly Overview
Assembly overview
Engines: AEG, AVH, AZG
Engines: AEG, AVH, AZG with steel plate cylinder head gasket.
1. Plug
2. Seal
3. Breather housing
- Turn to right to remove
4. 10 Nm
5. Seal
- Replace if damaged
6. Bracket
7. Sealing plug, 15 Nm
- Always replace
8. O-ring
- Always replace
9. Union
10. Lifting eye
11. 20 Nm
12. Cylinder head gasket
- Always replace
- After replacement replace complete amount of coolant in system
13. 15 Nm
14. Rear toothed belt guard
15. Cylinder head
- Check for distortion; Refer to Fig. 1
16. Cylinder head bolt
- Always replace
17. Oil deflector
- Replace if damaged
- Before installing gasket, coat transition between bearing cap and cylinder head with D 454 300 A2.
18. Cylinder head cover gasket
19. Cylinder head cover
20. Reinforcing strip
21. Rear upper toothed belt guard
Engines: AEG, AVH, AZG with aluminum plate cylinder head gasket.
1. Plug
2. To intake manifold
3. Shaped hose
4. To intake manifold
- Only from model year 2002
5. O-ring
- Always replace
6. Sealing plug
7. Cylinder head bolt
- Always replace
8. Union
9. 10 Nm
10. O-ring
- Always replace
11. 20 Nm
12. Lifting eye
13. Cylinder head gasket
- Always replace
- After replacement replace complete amount of coolant in system
14. 15 Nm
15. 20 Nm
16. Rear toothed belt guard
17. Tooth belt
- Mark direction of rotation before removing
- Check for wear
- Do not kink
18. Cylinder head
- Check for distortion; Refer to Fig. 1
- After replacement replace complete amount of coolant in system
19. Oil deflector
20. Cylinder head cover gasket
- Replace if damaged
- Before instating gasket, coat transition between bearing cap and cylinder head with D 454 300 A2.
21. Cylinder head cover
22. 10 Nm
23. Seal
Engines: APK, AQY
1. Plug
2. Seal
3. Breather housing
- Turn to right to remove
4. 10 Nm
5. Seal
- Replace if damaged
6. Bracket
7. Sealing plug, 15 Nm
- Always replace
8. O-ring
- Always replace
9. Union
10. Lifting eye
11. 20 Nm
12. Cylinder head gasket
- Always replace
- After replacement replace complete amount of coolant in system
13. 15 Nm
14. Rear toothed belt guard
15. Cylinder head
- Check for distortion; Refer to Fig. 1
- After replacement replace complete amount of coolant in system
16. Cylinder head bolt
- Always replace
17. Oil deflector
18. Cylinder head cover gasket
- Replace if damaged
- Before instating gasket, coat transition between bearing cap and cylinder head with D 454 300.
19. Cylinder head cover
20. Reinforcing strip
Engine: BBW
1. Cover
2. O-ring
- Always replace
3. Camshaft Position (CMP) sensor -G40
4 9 Nm
5. To intake hose
6. Shape hose
- Do not separate shape hose/intake hose
7. To intake manifold
8. Seal
- Installed firmly onto Item - 9 -
9. Sealing plug-15 Nm
- Always replace
10. Cylinder head bolt
- Replace
11. Union
12. 10 Nm
13. Seal
- Always replace
14. 20 Nm
15. Lifting eye
16. Cylinder head gasket
- Replace
- After replacement replace complete amount of coolant in system
17. Cylinder head
- Check for distortion; Refer to Fig. 1
- After replacement replace complete amount of coolant in system
18. 15 Nm
19. Rear toothed belt guard
20. 20 Nm
21. Washer
- Note Part No.
22. Toothed belt
- Mark direction of rotation before removing
- Check for wear
- Do not kink
23. O-ring
- Always replace
24. Valve -1- for camshaft adjustment -N205
- Controlled by engine control module
25. 9 Nm
26. Oil deflector
27. Cylinder head gasket
- Replace if damaged
- Coat cylinder head/bearing cap transition points with D 454 300 A2 before installing
28. Cylinder head cover
- With cable guide
29. 10 Nm
30. Seal
Engine: BEJ. BER, BEV, BHP
1. Cover
2. Seal
3. 10 Nm
4. To intake manifold
5. Shape hose
- Engines: BEJ, BER, BHP
6. Shape hose Engines: BEV
- Do not separate shape hose/intake hose
7. To intake manifold
8. O-ring
- Always replace
9. Sealing plug-15 Nm
- Always replace
10. Cylinder head bolt
- Always replace
11. Union
12. 10 Nm
13. Seal
- Always replace
14. 20 Nm
15. Lifting eye
16. Cylinder head gasket
- Always replace
- After replacement replace complete amount of coolant in system
17. 15 Nm
18. 20 Nm
19. Rear toothed belt guard
20. Toothed belt
- Mark direction of rotation before removing
- Check for wear
21. Cylinder head
- Check for distortion; Refer to Fig 1
- After replacement replace complete amount of coolant in system
22. Oil deflector
23. Cylinder head cover gasket
- Replace if damaged
- Coat cylinder head/bearing cap transition points with D 454 300 A2 before installing
24. Cylinder head cover
- With cable guide
Fig. 1 Checking cylinder head for distortion
Max permissible distortion: 01 mm (minimum distance between linear measurements: 100 mm)