Necessary preliminary tasks
- Remove EXHAUST SYSTEM
- Drain COOLANT
- Drain off ENGINE OIL
- Remove both EXHAUST MANIFOLDS
- Remove INTAKE PLENUM
- Detach coolant hoses from cylinder head
- Remove INTAKE AND EXHAUST CAMSHAFT ADJUSTERS
Do not wash off bolt coating.
There must be no fluids or contaminants in any of the threaded holes for the cylinder head bolt connections.
Risk of corrosion and cracking!
Apply a light coat of oil to washer contact areas and threads of new cylinder head bolts.
Release screws (1).
Unclip timing chain module (2) at junction (3) and remove towards top.
Set down timing chain.
This would cause the timing chain on the crankshaft sprocket wheel to jam or jump.
Installation:
The timing chain is lifted out with a hook only during assembly.
Release bolts (2) for eccentric shaft sensor (1).
Remove eccentric shaft sensor (1) towards front.
Release screw (1).
Remove magnet wheel (2) towards front.
After removing, place magnet wheel (1) in a plastic bag (2) with a seal.
Pre-tension eccentric shaft (1) upwards in direction of arrow.
Remove stop screw between 1st and 2nd cylinders.
Tightening torque 11 37 5AZ .
Release screw (2).
Tightening torque 11 12 3AZ .
Release screws (1).
Tightening torque 11 12 4AZ .
Installation:
Replace aluminum screws.
Release cylinder head bolts (1) M10 with special tool 11 8 580 .
Release cylinder head bolts (2) M9 with special tool 11 4 420 .
Undo cylinder head bolts (1 and 3) M9 using special tool 11 4 420 .
Tightening torque 11 12 2AZ .
Release cylinder head bolts (2) M10 with special tool 11 8 580 from outside inwards.
Tightening torque 11 12 1AZ .
Joining torque and angle of rotation must be observed without fail.
Risk of damage!
Secure special tool 11 0 320 with existing cylinder head cover bolts (1).
Tightening torque 11 12 5AZ .
Weight of cylinder head with add-on parts is approx. 40 kg.
Do not rest cylinder head on sealing surface. Risk of damage to valves!
Insert 11 4 430 special tool into bores.
Remove coarse residues on sealing surfaces with special tool 11 4 471 from cylinder head and crankcase.
Remove fine residues on sealing surfaces with special tool 11 4 472 from cylinder head and crankcase.
There must be no fluids or contaminants in any of the threaded holes (1) for the cylinder head bolt connections.
Risk of corrosion and cracking!
Clean all threaded holes.
Replace CYLINDER HEAD GASKET .
Fit new cylinder head screws.
Insert cylinder head bolts (1 to 10) with special tool 11 8 580 .
Tightening torque 11 12 1AZ .
Insert cylinder head bolts (11 to 14) with special tool 11 4 420 .
Tightening torque 11 12 2AZ .