Cylinder Head, Removing And Installing: Removing

WARNING: This page is about a different variant/trim than selected.

NOTE:

Before installing the cylinder head the engine support and the engine mount are temporarily re-installed because the eyes from the engine support bridge are secure on the cylinder head.

When installing, secure all cable ties back to same positions.

Close the open channels from the intake and exhaust tract with suitable plugs from the : VAS6122 .

-- Remove the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

-- Reinstall the engine support and engine mount and tighten the bolts hand-tight.

-- Disengage the : 10-222A spindles.

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

-- Remove the front exhaust pipe with catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Remove the Oxygen Sensor 1 before Catalytic Converter -GX10-. Refer to Oxygen Sensor 1 before Catalytic Converter -GX10-, REMOVING AND INSTALLING .

-- Remove the bolt -arrow- on the left and right.

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-- Unclip and remove the lower section -1- of the air duct.

-- Loosen the hose clamp -2- and remove the air duct hose from the charge air cooler.

Fig 1: Identifying Clamps

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-- Seal the open lines and connections with clean plugs from the : VAS6122 .

-- Remove the air duct pipe. Refer to AIR DUCT PIPE FROM CHARGE AIR COOLER TO INTAKE MANIFOLD, REMOVING AND INSTALLING .

Fig 2: Disconnect Charge Air Pressure Sensor Connector

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-- Loosen the hose clamps -arrows- and remove the coolant hoses.

Fig 3: Identifying Clamps And Coolant Hoses

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-- Pivot the coolant line -1- to the side.

-- Disconnect the connectors:

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1 - For the Oil Pressure Switch -F22-

2 - For the Reduced Oil Pressure Switch -F378-

5 - For the Piston Cooling Nozzle Control Valve -N522-

-- Remove the bolts -arrows-.

Fig 4: Locating Air Guide Pipe Bolts

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-- Remove the bolt -1- and the nut -3- and then remove the bracket -2- for the intake manifold.

Fig 5: Identifying Bolt And Nut

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-- Disconnect the connectors:

Fig 6: Disconnect Connectors

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For the Throttle Valve Control Module -GX3-
For the Intake Manifold Sensor -GX9-
For the Fuel Pressure Sensor -G247-

-- Remove the connector -4- from the bracket.

-- Free up the wiring harness and push it to the side.

-- Free up the wiring harness -1 and 2- from the air guide pipe.

Fig 7: Free Up Wiring Harness From Air Guide Pipe

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-- Loosen the screw-type clamp -3-.

-- Remove the bolts -arrows-.

-- Loosen the hose clamp -arrow- and remove the charge air hose -1- with the air guide pipe downward.

Fig 8: Charge Air Hose Clamp Location

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-- Remove the connector -3- for the Knock Sensor 1 -G61- from the bracket and disconnect it.

Fig 9: Knock Sensor Connector Locations

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-- Disconnect the connectors -2 and 4-.

-- Disconnect the connectors and free up the wires.

Fig 10: Disconnecting Knock Sensor Connectors

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For the Intake Manifold Runner Control Valve -N316-
For the Coolant Shut-Off Valve -N82-
For the Engine Coolant Temperature Sensor -G62-
For the Oil Pressure Switch, Level 3 -F447-

-- Remove the bolts -arrows-.

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

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-- Remove the heat shield -2-.

-- Remove the bolt -1-. Only loosen the bolt -3-.

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-- Remove the turbocharger bracket -2-.

-- Remove the nuts -arrows-.

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-- Remove the turbocharger from the cylinder head and tie up toward the rear.

-- Remove the bolts -arrows-.

Fig 11: Cylinder Head Loosening Sequence

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

NOTE:

Make sure all wires and cables are disconnected.

-- Remove the cylinder head and place it on a soft surface (foam).