Cylinder Head, Removing And Installing: Removing

• During installation, install all heat insulation sleeves at the same locations.

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

-- Remove the front upper coolant pipes. Refer to UPPER COOLANT PIPES, REMOVING AND INSTALLING .

-- Remove the rear coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the left coolant pipes. Refer to LEFT COOLANT PIPES, REMOVING AND INSTALLING .

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

-- Remove the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and the resonator -1-.

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-- Remove the connector -2- for the EGR Temperature Sensor -G98- from the retainer, disconnect it and free up the wire.

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Vehicles with Auxiliary Heater

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-- Lift the clamps -1 and 2-, loosen the hose clamps -3-, and remove the coolant hoses.

-- Remove the nuts -arrows- and the coolant pipes.

Continuation for All Vehicles

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-- Disconnect the connectors and free up the wires.

1. For Exhaust Gas Temperature Sensor 4 -G648-
2. For Exhaust Gas Temperature Sensor 3 -G495-
3. For Exhaust Gas Temperature Sensor 2 -G448- Equipped Depending on the Exhaust Gas Standard

-- Remove the connector for the Heated Oxygen Sensor -G39- -4- from the bracket, disconnect it and free up the wire.

AWD Vehicles

-- Remove the exhaust gas recirculation. Refer to EGR COOLER, REMOVING AND INSTALLING .

Vehicles with FWD

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• Use the : T40207  to disconnect the connector -2- in illustration "A15-11651". Disconnect the securing pin on the connector housing -1- in direction of -arrow-.

-- Loosen the clamp -1- and remove the air guide hose.

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-- Push the heat shield boot aside, disconnect the connector -2- and free up the wire.

All Vehicles

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-- Loosen the double bolt -1-, push the coolant pipe slightly toward the rear.

-- Remove the bolts -2-, and push the emissions control module and on front wheel drive vehicles the Exhaust Gas Recirculation (EGR) cooler rearward.

-- Remove the bolt -2- and union nut -4-.

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-- Remove bolts -3 and 5- and the oil return pipe.

-- Remove the bolt -2-, and only loosen the bolts -1, 3, and 4-.

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Vehicles with Variable Valve Timing: 

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-- Disconnect the connectors -1 and 3-.

-- Loosen the hose clamp -2-.

Continuation for All Vehicles:

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-- Disconnect the connectors and free them up:

1 - For Charge Air Temperature Sensor After Charge Air Cooler -G811-

3 - For Charge Air Pressure Sensor -G31-

4 - For Charge Air Temperature Sensor In Front Of Charge Air Cooler -G810-

5 - For Throttle Valve Control Module -J338-

-- Remove the bolts -2 and 7-, and remove the coolant hose -6-.

-- Place the left front coolant pipe aside.

-- Remove the bolt -1- for the oil dipstick guide tube.

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-- Remove the bolts -2 and 3- for the intake manifold bracket.

Vehicles with Variable Valve Timing:

-- Remove the Throttle Valve Control Module -J338-. Refer to Throttle Valve Control Module -J338-, REMOVING AND INSTALLING .

Continuation for All Vehicles:

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-- Disconnect the connector -3-.

-- Remove the bolt -1-, and leave the cover -2- in it installed position.

-- Open the retainer in direction of -arrow- and remove the vacuum hose -1-.

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-- Disconnect vacuum hose -2-.

-- Remove the bolt -3-.

• Depending on the vehicle, there are different components.

-- Disconnect the connector -2- for the Engine Coolant Temperature Sensor -G62-.

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-- Loosen the clamp -1- and remove the coolant hose.

-- Disconnect vacuum hose -3-.

-- Disconnect the connector for the glow plug. Refer to GLOW PLUG, REMOVING AND INSTALLING .

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-- Move the electrical wiring harness to the side.

-- Loosen the cylinder head bolts in the sequence -1 to 10-.

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• A second technician is needed to remove the cylinder head.

-- Move the cylinder head from the rear toothed belt guard toward the left and remove the tensioning roller at the same time.

-- Be careful not to damage the turbocharger oil return line.

-- Lay the cylinder head down being careful not to bend the oil return line. Place a piece of wood under the exhaust manifold if necessary.

• Do not lay the removed cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface.