Cylinder Head

Special tools and workshop equipment required

Engine Bung Set VAS 6122
Hose Clip Pliers VAS 6362
Polydrive Bit and Drive Socket T10070 or socket XZN M12, minimum 140 mm, commercially available
Camshaft Clamp T40070

Removing

Fig 1: Identifying Ground Wire Terminal Clamp, Removal

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NOTE:

When installing, bring all cable ties back to same positions.

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe measures for disconnecting battery.

-- With the ignition switched off, disconnect the battery Ground (GND) -arrow-. Refer to [For transmission(s) 02E] Removal and Installation .

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Remove the noise insulation frame -arrow- and the rear noise insulation. Refer to Removal and Installation .

Fig 2: Identifying Noise Insulation Frame

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-- Disconnect the connector -1- in order to cut the cable tie -arrows-.

Fig 3: Locating Connectors On Cylinder Head

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-- Remove electrical harness connectors -2 and 3- from bracket and disconnect.

-- Free up the wiring harness.

-- Remove the nuts -1- and remove the right drive axle heat shield.

Fig 4: Identifying Installation Of Heat Shield

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-- Remove the bolts -1 and 2-.

Fig 5: Identifying Air Guide Pipe

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-- Remove the air guide pipe, to do so, loosen the hose clamps -arrows-.

NOTE:

Lay a cloth below to catch escaping coolant and engine oil.

Fig 6: Locating Hose Bolts

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-- Remove bolts -1, 2 and 3- and banjo bolt -4- and remove wires from the cylinder block.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

-- Remove the upper section of the intake manifold. Refer to Removal and Installation .

Fig 7: Identifying Intake Manifold Upper Section, Tightening Sequence

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WARNING:

Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening the fuel system and carefully loosen.

CAUTION:

Danger of defects caused by dirt.

Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

-- Remove the fuel supply line mount, then remove the heat shield boot -2- from the fuel supply line at the separating point.

Fig 8: Locating Fuel Supply Line

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-- Disconnect the fuel supply line in order to pull the release ring.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

-- Remove the hose -1- from the EVAP canister.

NOTE:

Ignore -arrows A and B-.

-- Remove the bolt -4- and free up the Ground (GND) cable.

Fig 9: Locating Camshaft Position Sensor & Fuel Metering Valve

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-- Disconnect the connectors:

1 - Wastegate bypass regulator valve -N75-

2 - Camshaft Position (CMP) sensor 3 -G300-

3 - Fuel Metering Valve -N290-

5 - Camshaft adjustment valve 1 -N205-

-- Free up the wiring harness.

-- Disconnect the connector -1-.

Fig 10: Identifying Exhaust Gas Temperature Sensor

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-- Remove the bolts -arrows- and remove the exhaust gas temperature sensor 1 -G235- on the cylinder head.

-- Remove the bolt -1-.

Fig 11: Disconnecting Vacuum Hose

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-- Disconnect the vacuum hose -2- and free it up.

-- Remove the oil dipstick -2-.

Fig 12: Identifying Oil Dipstick Guide Tube - Tightening Specifications

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-- Remove the bolts -arrows-, then remove oil dipstick tube -1- upward.

-- Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

-- Remove and disconnect the connector -1- for the Heated Oxygen Sensor (HO2S) -G39-.

Fig 13: Disconnecting Heated Oxygen Sensor (HO2S) Electrical Harness Connector

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-- Free up the heated oxygen sensor wire.

NOTE:

Ignore -2 and 3-.

-- Loosen the bolt -3- and slide the clamp onto the primary catalytic converter.

Fig 14: Identifying Primary Catalytic Converter

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-- Remove the bolt -2- and tie up the primary catalytic converter toward the rear.

NOTE:

Ignore -1-.

-- Remove the bolts -arrows-.

Fig 15: Locating Bolts

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NOTE:

Ignore -1-.

-- Loosen and tighten cylinder head bolts in -13 to 1- sequence.

Fig 16: Identifying Cylinder Head, Tightening Sequence

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NOTE:

If bolt -12- cannot be removed with a magnet, loosen the T40070 bolt one turn, slide the T40070 forward and to the right and then tighten it again.

A second technician is required to remove the cylinder head.

-- Remove the cylinder head.

CAUTION:

The engine could be destroyed.

To prevent small parts from accidentally entering the engine through the opening in the timing chain compartment, seal the opening with a clean cloth.

Risk of damaging the cylinder wall.

Stuff clean cloths into the cylinder to prevent sanding and grinding residue from getting between the cylinder wall and the pistons.

Installing

Fig 17: Identifying Camshaft Clamp T40070

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For the correct tightening specifications, refer to CYLINDER HEAD COVER AND CYLINDER HEAD OVERVIEW .
Camshafts locked using the T40070.

CAUTION:

The sealing surfaces could be damaged.

Carefully remove sealant residue from cylinder head and cylinder block.
Make sure that no long scrapes or scratches result.

Risk of damaging cylinder block.

No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.

Risk of leaks in cylinder head seal.

Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
Carefully remove all grinding and sanding residue.
Only unpack new cylinder head gasket immediately prior to installation.
To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.

Risk of damaging open valves.

If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.

NOTE:

Replace bolts that are tightened to the specification.

Replace self-locking nuts, sealing rings, seals and O-rings.

If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

-- Clean the sealing surfaces; they must be free of oil and grease.

NOTE:

Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter approximately 2.0 mm).

Fig 18: Cutting Tube Nozzle At Front Marking (Nozzle Diameter Approx. 2.0 mm)

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Fig 19: Identifying Cylinder Block Surface

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than indicated.

-- Apply sealant beads -1 and 2- on the clean surfaces of the cylinder block as shown in the illustration.

Thickness of sealant bead: 2.0 to 2.5 mm.

-- Set cylinder head gasket in place.

Fig 20: Identifying Centering Pins In Cylinder Block

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Installed position: It must be possible to read the part number.
Pay close attention to alignment bushings in cylinder block -arrows-.

-- Apply sealant bead -2- to the cylinder head gasket -1- as illustrated.

Fig 21: Identifying Cylinder Head Gasket

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NOTE:

The cylinder head must be installed within 5 minutes after applying the sealant.

-- Set cylinder head in place.

Fig 22: Identifying Cylinder Head, Tightening Sequence

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-- Tighten the cylinder head bolts. Refer to Figure.

NOTE:

Do not tighten cylinder head bolts after repairs.

-- Wipe off any sealant that leaks out.

Install in reverse order of removal paying attention to the following:

-- Install primary catalytic converter. Refer to PRIMARY CATALYTIC CONVERTER .

-- Install camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

-- Tighten the oil dipstick guide tube. Refer to Fig 23.

Fig 23: Identifying Oil Dipstick Guide Tube - Tightening Specifications

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-- Install the exhaust gas temperature sensor 1 -G235-. Refer to Exhaust Gas Temperature (EGT) Sensor 1 -G235- .

-- Install the upper section of the intake manifold. Refer to Removal and Installation .

-- Install the turbocharger. Refer to TURBOCHARGER OVERVIEW .

-- Install the driveshaft heat shield. Refer to Removal and Installation .

-- Install the noise insulation frame. Refer to Removal and Installation .

-- Electrical connectors and wiring routing. Refer to appropriate SYSTEMS WIRING DIAGRAM.

-- Follow measures after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

-- Change engine oil. Refer to MAINTENANCE PROCEDURES

-- Replace coolant. Refer to COOLANT, DRAINING AND FILLING .