Cylinder Head, Removing And Installing, 1.8L Engine: Installing

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.

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

Risk of cylinder head seal leaking.

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.

Risk of damaging valves and piston heads after working on valve train.

To ensure valves do not strike pistons when starting, carefully rotate engine at least two full revolutions.

NOTE:

Replace the bolts which are being tightened with an additional turn.

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 camshafts.

The hose supports, 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.

It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.

When using a new cylinder head

Fig 1: Mark Camshaft Sprocket

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-- Mark the camshaft sprocket to the Camshaft Lock - Component 1 T40271/1 and the Camshaft Lock - Component 2 T40271/2 -arrow-.

-- Turn the intake camshaft with a wrench in the -direction of arrow 1-, slide the Camshaft Lock - Component 2 T40271/2 out of the chain sprocket splines in -direction of arrow 2- and bring the camshaft into the rest position.

Fig 2: Turn Intake Camshaft With A Wrench In Direction Of Arrow

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-- Remove the Camshaft Lock - Component 2 T40271/2.

-- Turn the exhaust camshaft with a wrench in the -direction of arrow 1-, slide the Camshaft Lock - Component 1 T40271/1 out of the chain sprocket splines in -direction of arrow 2- and bring the camshaft into the rest position.

Fig 3: Turn Exhaust Camshaft With A Wrench In Direction Of Arrow

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-- Remove the Camshaft Locks - Component 1 T40271/1.

-- Transfer the self-made markings from the old camshafts to the new camshafts.

-- Install the Camshaft Lock - Component 2 T40271/2 on the cylinder head.

Fig 4: Attach T40271/2 To Cylinder Head

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-- Turn the intake camshaft in -direction of arrow 1- until the marking -3- aligns with the Camshaft Lock - Component 2 T40271/2.

-- Slide the Camshaft Lock - Component 2 T40271/2 into the chain sprocket splines in the -direction of arrow 2-.

-- Install the Camshaft Lock - Component 1 T40271/1 on the cylinder head.

Fig 5: Attach T40271/1 To Cylinder Head

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-- Turn the exhaust camshaft in the -direction of arrow 1- until the marking -3- aligns with the Camshaft Lock - Component 1 T40271/1.

-- Slide the Camshaft Lock - Component 1 T40271/1 into the chain sprocket splines in the -direction of arrow 2-.

All

Fig 6: Identifying Centering Pins

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-- Set cylinder head gasket in place.

Pay attention to centering pins in cylinder block -arrows-.
Cylinder head gasket installed position: the part number must be readable from the intake side.

WARNING:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- If the crankshaft was turned in the meanwhile: bring the piston for cylinder 1 to TDC and then turn the crankshaft back just a little.

-- Set cylinder head in place.

-- Insert cylinder head bolts and tighten by hand.

-- Cylinder head tightening sequence Figure.

NOTE:

There is no requirement to tighten the cylinder head bolts after repairs.

-- Rotate the vibration damper using the Counterhold - Vibration Damper T10355 into the "TDC" position -arrow-.

Fig 7: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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The notch on the vibration damper must line up with the arrow marking on the lower timing chain cover.

-- Position the markings on the chain links -arrows- at the chain sprockets -1- to mount the camshaft timing chain.

Fig 8: Identifying Markings On Chain Links

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-- Install the upper guide rail -2-.

-- Turn the exhaust camshaft in -direction of arrow 1-, slide the Camshaft Locks T40271/1 out of the chain sprocket splines in -direction of arrow 2- and release the camshaft.

Fig 9: Turn Exhaust Camshaft

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-- Remove the Camshaft Locks - Component 1 T40271/1.

-- Guide the tensioning rail -2- upward and install the bolt -1-.

Fig 10: Identifying Tensioning Rail Bolt

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-- Turn the intake camshaft in -direction of arrow 1-, slide the Camshaft Locks - Component 2 T40271/2 out of the chain sprocket splines in -direction of arrow 2- and release the camshaft.

Fig 11: Turn Intake Camshaft

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-- Remove the Camshaft Lock - Component 2 T40271/2.

-- Check the valve timing. The camshaft timing chain and cylinder head -arrows- must align with the markings on the chain sprockets -1-.

Fig 12: Check Valve Timing

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-- The markings for the camshaft timing chain and the camshaft timing chain guide rail -2- must align.

-- The notch on the vibration damper must be opposite the marking on the lower timing chain cover -3-.

NOTE:

If the self-made markings are no longer visible, check the valve timing. Refer to VALVE TIMING, CHECKING .

-- Mount the bearing bracket and the bolts -arrows- hand-tight.

Fig 13: Bearing Bracket Bolts

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-- Depending on the version, remove either the Locking Pin (3 pc.) T40011 or the Tensioner Locking Tool T40267.

-- Tighten the bolts -arrows-. Refer to OVERVIEW - CAMSHAFT TIMING CHAINS .

-- Install the bolt -arrow-.

Fig 14: Identifying Bolt

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-- Install the control valve. Refer to -item 6- Control Valve (See Figure).

Further assembly is performed in the reverse order of removal, thereby observing the following:

-- Change the Engine Oil.

-- Install the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

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

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the front exhaust pipe/front muffler. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

WARNING:

Do not use a charger as a starting aid. There is the risk that the vehicle control modules could be damaged.