Cylinder Head, Removing And Installing, Engine Without Wrench Clearance: 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 camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

CAUTION:

Risk of damaging valves and piston crowns.

Do not turn the crankshaft if the camshaft has been removed.

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 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 in direction of -arrow-.

Fig 1: Disconnect Vacuum Connection

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

Fig 2: Identifying Fuel Line

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CAUTION:

Risk of contamination to the fuel system.

Note the rules of cleanliness for working on the fuel injection system. Refer to CLEAN WORKING CONDITIONS .

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

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

Fig 9: Identifying Bolts

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

-- Remove the spark plugs using a Spark Plug Removal Tool 3122B.

-- Remove the bolts -arrows-.

Fig 16: 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 10-.

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.