Component Overview

Fig 1: Identifying Cylinder Head Torx Screws

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1. External Torx screw, M6 x 25
2. External Torx screw, M6 x 80
3. Internal Torx screw, M12 x 1.5 x 140
4. External Torx screw, M12 x 1.5 x 140

Information 

• Position hydraulic tappets on a surface you have prepared and labelled yourself in accordance with their installation position in the cylinder head. 
• Components have been run in fitted bores and must not be confused. 
• Do not use magnets for removal or installation. This can cause the components to malfunction. 

1. Remove hydraulic tappets.
   1. 1.1. Pull six bucket tappets -1-  and six switching tappets -2-  out of the fitted bores in the cylinder head. Do not use magnets.
      Fig 2: Identifying Bucket Tappets And Switching Tappets

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   2. 1.2. Lay components on clean, labelled cardboard → Example of laying aside bucket tappets  and cover them.
      Fig 3: Example Of Laying Aside Bucket Tappets

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   3. 1.3. If you see any sign of wear, replace the affected hydraulic tappet.

   To remove cylinder head 1-3: 

2. Remove two bearing pins on the cylinder head - one at the top for the guide rail -1-  and one at the bottom for the tensioning rail -2-  .
   Fig 4: Identifying Bearing Pins

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   1. 2.1. Replace O-rings.
3. Unscrew three external Torx screws (E10, M6 x 25) -1-  on the outside of the cylinder head.
   Fig 5: Identifying External Torx Screws

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   1. 3.1. Unscrew four external Torx screws (E10) - three M6 x 25 screws -1-  and one M6 x 80 screw -2-  - on the inside of the cylinder head.
      Fig 6: Overview Of Screws For Cylinder Head 1-3

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   2. 3.2. Loosen two external Torx screws (M12 x 140) -3-  and six internal Torx screws (M12 x 140) -4-  from the outside in and unscrew them.

   To remove cylinder head 4-6: 

4. Pull off oil supply valve for vacuum pump -1-  and remove bearing pin for guide rail on the cylinder head -2-  .
   Fig 7: Identifying Vacuum Pump And Cylinder Head

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   1. 4.1. Replace O-rings.
5. Unscrew two external Torx screws (E10, M6 x 25) -1-  on the outside of the cylinder head.
   Fig 8: Identifying Screws On Outside Of Cylinder Head

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   1. 5.1. Unscrew four external Torx screws (E10) - three M6 x 25 screws -1-  and one M6 x 80 screw -2-  - on the inside of the cylinder head.
      Fig 9: Overview Of Screws For Cylinder Head

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   2. 5.2. Loosen two external Torx screws (M12 x 140) -3-  and six internal Torx screws (M12 x 140) -4-  from the outside in and unscrew them.
6. Lift off cylinder head.
   1. 6.1. Check the fitted bores of the hydraulic tappets for signs of wear. If you see signs of wear, the cylinder head and any worn tappets must be replaced.
   2. 6.2. Check the sealing face for signs of distortion and wear before re-installation and carry out approved repairs if necessary.
7. Remove and dispose of cylinder head gasket -1-  . Check dowel sleeves -2-  for signs of damage and replace if necessary.
   Fig 10: Identifying Cylinder Head Gasket

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8. If you need to disassemble the cylinder head further, remove the displacement bodies -1-  on cylinder bank 1-3 using flat-nosed pliers.
   Fig 11: Locating Piston Markings

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