Cylinder Head and Cover Overview
Cylinder Head and Cover Overview
• When installing a replacement cylinder head, all of the contact surfaces between the supports, roller rocker levers and cam running surfaces on the camshaft must be lubricated before installing the cylinder head cover.
• The plastic protectors installed to protect the open valves must only be removed immediately before mounting the cylinder head.
• The entire amount of coolant must be replaced when replacing the cylinder head. Refer to => [ Draining and Filling ] Draining and Filling.
• Intake manifold, removing and installing. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
• Intake manifold overview. Refer to => [ Intake Manifold Overview ] Intake Manifold Overview.
1 Bolt
• 10 Nm
2 Bracket
• For fuel lines
3 Bolt/Nut
• 10 Nm
• With a spacer sleeve and seal
• Replace seal if damaged
4 Cover
• Replace the seal - 5 - if damaged
5 O-ring
• Replace if damaged
• Lubricate before assembling.
• For the cap - 4 -.
6 Cylinder Head Cover
• Removing and installing, refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
• Replace if damaged
7 Lifting Eye
8 Bolt
• 23 Nm
9 Camshaft Timing Chain
• Mark direction of rotation before removing (installed position). Refer to => [ Timing Chain Marks ] Chain Drive and Cylinder Block and Lubrication Overview.
• Installing, refer to => [ Intermediate Shaft and Timing Chains, Installing ] Intermediate Shaft and Timing Chains, Installing.
10 Combination Valve
• Checking, refer to one of the following:
Engine code BUB, refer to => [ Secondary Air Injection Combination Valve, Checking ] Secondary Air Injection Combination Valve, Checking.
Engine code CBRA, refer to => [ Secondary Air Injection Combination Valves, Checking ] Service and Repair.
• Removing and installing
Engine code BUB, refer to => [ Combination Valve ] Combination Valve.
Engine code CBRA, refer to => [ Left Combination Valve ] Left Combination Valve, or => [ Right Combination Valve ] Right Combination Valve.
11 Camshaft Adjustment Valve 1 (N205)
• For the intake camshaft
• Removing and installing, refer to => [ Camshaft Adjuster Valves ] Camshaft Adjuster Valves.
• Mark the connector belonging to the component before disconnecting
12 Exhaust Camshaft Adjustment Valve 1 (N318)
• For exhaust camshaft
• Removing and installing, refer to => [ Camshaft Adjuster Valves ] Camshaft Adjuster Valves.
• Mark the connector belonging to the component before disconnecting
13 O-ring
• For oil channel seal
• Replace
• Lubricate before assembling.
14 Camshaft Position (CMP) Sensor 2 (G163)
• For exhaust camshaft
• Mark the connector belonging to the component before disconnecting
15 Chain Tensioner
• 40 Nm
• For the camshaft timing chain => [ (Item 9) Camshaft Timing Chain ]
• Only rotate engine with chain tensioner installed
16 Seal
• Replace if damaged or leaking
17 Bolt
• 8 Nm
18 Seals
• For the camshaft adjustment valve 1 => [ (Item 11) ] and exhaust camshaft adjustment valve 1 => [ (Item 12) ]
• Replace if damaged or leaking
• Installing, refer to => [ Camshaft Front Cover Seal, Installing ] Service and Repair.
19 Coolant Thermostat Housing
• Overview, refer to => [ Coolant Thermostat Housing Overview ] Coolant Thermostat Housing Overview.
• Coolant hose connection diagram. Refer to => [ Coolant Hose Connection Diagram ] [1][2]Cooling System.
20 Seal
• Replace
21 Camshaft Position (CMP) Sensor (G40)
• For intake camshaft
• Mark the connector belonging to the component before disconnecting
22 Cover
• Can be removed and installed with the engine installed
• Removing and installing, refer to => [ Camshaft Front Cover Overview ] Service and Repair.
• If only the cover was removed, prepare the cylinder head gasket for installation, refer to => [ Cylinder Head Gasket, Preparing for Assembly ] Cylinder Head.
• With O-ring => [ (Item 13) O-ring ] for oil channel seal.
23 Bolt
• Replace
• 60 Nm + 90° (1/4) additional turn.
• Contact surface of sensor wheel at bolt head must be dry when installing
• To remove and install, counter-hold at camshaft using a 32 mm open end wrench. Refer to=> [ Camshafts ] Service and Repair.
24 Exhaust Camshaft Adjuster
• Identification: 32A
• Only rotate the engine with camshaft adjuster installed
• Installing, refer to => [ Camshaft Adjuster with Camshaft Timing Chain, Installing ] Camshaft Adjuster with Camshaft Timing Chain, Installing.
25 Guide Rail
• For the camshaft timing chain => [ (Item 9) Camshaft Timing Chain ].
• Clipped to the control housing.
26 Intake Camshaft Adjuster
• Identification: 24E
• Only rotate engine with camshaft adjuster installed
• Installing, refer to => [ Camshaft Adjuster with Camshaft Timing Chain, Installing ] Camshaft Adjuster with Camshaft Timing Chain, Installing.
27 Lifting Eye
28 Cylinder Head Gasket
• Metal
• Replace
• Prepare the cylinder head gasket for installation. Refer to => [ Cylinder Head Gasket, Preparing for Assembly ] Cylinder Head.
• After replacing replace entire amount of coolant
29 Cylinder Head
• Check for distortion, refer to => [ Checking Cylinder Head for Distortion ].
• Removing and installing, refer to => [ Cylinder Head ] Cylinder Head.
• After replacing replace entire amount of coolant
30 Tensioning Element
• For the ribbed belt
• Removing and installing ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.
31 Cylinder Head Bolt
• Replace
• Observe installation instructions and sequence for loosening and tightening. Refer to => [ Cylinder Head ] Cylinder Head.
32 Cylinder Head Cover Gasket
• Replace if damaged or leaking
• Note the installed position.
Checking Cylinder Head for Distortion
Special tools, testers and auxiliary items required
• Straight edge 500 mm (VAS 6075)
• Feeler gauge
Max. permissible distortion: 0.05 mm