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

NOTE:

During installation, cable ties must be installed at the same location.

Always seal off any open channels in the intake and exhaust tract with suitable plugs. For example, from the Engine Bung Set VAS6122.

-- Remove the front noise insulation. Refer to Front Noise Insulation .

WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

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

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

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the plenum chamber cover. Refer to Bulkhead .

-- Disconnect the vacuum connection -2- from the plenum chamber bulkhead by remove the vacuum hose -3- on the back side -arrow-.

Fig 1: Disconnect Vacuum Connection

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-- Remove the coolant hoses on the back of the cylinder head.

-- Disconnect the fuel lines -1 and 2-.

Fig 2: Identifying Fuel Line

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CAUTION:

Follow the guidelines for cleanliness when working on the fuel supply system.

-- Perform a service position. Refer to SERVICE POSITION, PERFORMING AND RESETTING .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Loosen the hose clamps -arrows- and remove the air guide hose.

Fig 3: Identifying Air Intake Hose Components

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-- Disconnect the following connectors.

Fig 4: Connectors

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2 -disconnect from the Knock Sensor 1 -G61- and free up.

3 -from the Intake Manifold Runner Control Valve - N316-, Fuel Pressure Sensor - G247- and Camshaft Position Sensor - G40-.

4 -from the fuel injectors

5 -from the Throttle Valve Control Module - J338-.

6 -From the Intake Air Temperature Sensor - G42-.

-- Disconnect the connector -2- and free up the wire.

Fig 5: Generator Electrical Connector And Terminal B+

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-- Remove the coolant line bracket -arrow-.

Fig 6: Locating Coolant Line Bolt

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NOTE:

The engine is not shown in the illustrations that follow.

-- Remove the intake manifold bracket by removing the mounting nut -1- and bolt -2-.

Fig 7: Identifying Intake Manifold Bracket Mounting Nut & Bolt

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-- Disconnect the coolant hose -arrow-.

Fig 8: Disconnecting Coolant Hose

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-- Remove the screws -1 and 2- and move the oil supply line to the side.

Fig 9: Identifying Bolts

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-- Remove the screw -3- and move the coolant line to the side.

-- Loosen the hose clamp -arrow-, pull of the air guide hose and move it to the side.

Fig 10: Identifying Hose Clamp

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-- Disconnect the connectors -1 and 4- from the Oil Pressure Switch - F22- and Reduced Oil Pressure Switch - F378-.

Fig 11: Identifying Oil Pressure Switch

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-- Disconnect the connectors -1 and 2- and free up the wire.

Fig 12: Disconnect Connectors

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-- Loosen the bolts -1- from above.

Fig 13: Identifying Bolts

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-- Remove the bolt -2- from below.

-- Remove the screws -arrows- on the oil return line.

Fig 14: Identifying Bolts

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-- Remove the nuts -arrows- and push the catalytic converter to the rear.

Fig 15: Identifying Nuts

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-- Disconnect the connector from Camshaft Adjustment Valve 1 -N205- -1-.

Fig 16: Disconnect Connector

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-- Remove the bolts -arrows- and then the Camshaft Adjustment Valve 1 -N205-.

-- Remove the bolts -1 through 5- and the upper timing chain cover.

Fig 17: Identifying Upper Timing Chain Cover - Tightening Sequence

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Fig 18: Identifying Assembly Tool T10352 To Remove Control Valve

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CAUTION:

The control valve has a left thread.

-- Remove the control valve in the -direction of the arrow- with the Central Valve Assembly Tool T10352 or Central Valve Assembly Tool T10352/1, depending on the version.

-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 19: Bearing Bracket Bolts

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

Fig 20: Identifying Markings -1- On Camshafts Aligned To Point Upward

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The notch on the vibration damper and the marking on the lower cover for timing chain must be opposite one another -arrow-.
The markings -1- on the camshafts must point upward.

-- Mark the camshaft timing chain and the cylinder head -arrows- to match the marking on the chain sprockets -1- with a waterproof marker.

Fig 21: Mark camshaft timing chain and the cylinder head

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-- In addition, mark the camshaft timing chain to the camshaft timing chain guide rail -2- with a permanent marker.

-- Remove the plug -arrow-.

Fig 22: Identifying Plug

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-- Remove the bolts -arrows-.

Fig 23: Identifying Bolts

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-- Remove the bolt -arrow-.

Fig 24: Identifying Bolt

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Two different chain tensioners may be installed depending on the version:

Fig 25: Identifying Version 1

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Version 1

-- Install the Chain Tensioner Lever T40243 -arrows-.

-- Lift up the locking wedge for the chain tensioner by inserting a scriber or a suitable screwdriver into the chain tensioner opening in -direction of arrow 1-. Slowly press and hold the Chain Tensioner Lever T40243 in -direction of arrow 2-.

-- Secure the chain tensioner using the Locking Pin (3 pc.) T40011.

Fig 26: Securing Chain Tensioner

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Version 2

Fig 27: Identifying Version 2

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-- Install the Chain Tensioner Lever T40243 -arrows-.

-- Press the chain tensioner locking ring -1- together and slowly press and hold the Chain Tensioner Lever T40243 in -direction of arrow-.

-- Secure the chain tensioner with the Tensioner Locking Tool T40267.

Fig 28: Securing Chain Tensioner

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All Versions

Fig 29: Bolt Camshaft Locating Tool

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-- Remove the Chain Tensioner Lever T40243.

-- Bolt the Camshaft Locks - Component 2 T40271/2 to the cylinder head and push the chain sprocket splines in the -direction of arrow 2-. If necessary, turn the intake camshaft with a wrench in -direction of arrow 1-.

-- Remove the bolt -1- and guide the tensioning rail -2- downward.

Fig 30: Identifying Tensioning Rail Bolt

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

Fig 31: Attach T40271/1 To Cylinder Head

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-- Turn the exhaust camshaft with the wrench in the -direction of arrow 1- and slide the Camshaft Locks T40271/1 into the chain sprocket splines in -direction of arrow 2-.

-- Remove the upper guide track -arrow- by unlocking the latch with a screwdriver and pushing the guide track forward.

Fig 32: Identifying Upper Guide Track

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-- Remove camshaft timing chain from chain sprockets.

CAUTION:

Risk of damaging valves and piston crowns.

If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.

-- Remover the ignition coils with the power output stages. Refer to IGNITION COILS WITH POWER OUTPUT STAGES, REMOVING AND INSTALLING .

-- Disconnect the crankcase ventilation hose -1-.

Fig 33: Locating Crankcase Ventilation Bolts

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-- Remove the screws -arrows- and then remove the crankcase ventilation from the hose -2- in -direction of arrow-.

-- Turn the sealing plug -arrows- counterclockwise 90° in the -direction of the arrow- and remove it.

Fig 34: Ball Head And Sealing Plug

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-- Remove the ball head -1 through 2-.

-- Remove the cap.

-- Remove the bolts -arrows-.

Fig 35: Cylinder Head Loosening Sequence

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-- Remove the cylinder head bolts with the Polydrive Bit Drive Socket T10070 in the order -1 through 5-.

NOTE:

Make sure all wires and cables are disconnected.

Pay attention to the tension and guide tracks when lifting the cylinder head.

-- Remove the cylinder head.

-- Lay the cylinder head on a soft surface, such as foam.