Cylinder head/gasket, replacing

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1 1(16) Cylinder head/gasket, replacing Special tools: , , , , , , , , , Removing the cylinder head gasket Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct. Preparation The terms turbo 1 and turbo 2 are used to simplify the text below. Turbo 1 stands for the turbocharger for cylinders 1, 2 and 3. Turbo 2 stands for the turbocharger for cylinders 4, 5 and 6. the negative battery lead. First read Note when disconnecting/connecting the battery lead. the radiator breather tube by the expansion tank. lock grip pliers. the right drive shaft. See: Half shaft, right, replacing. the bearing seat for the drive shaft from the cylinder block. the pipe screw for the turbocharger oil pressure pipe by the cylinder block. Draining coolant Open the engine nipple. Drain the coolant into a container. Close the nipple. Separating the exhaust system the 8 nuts at the front exhaust system connection to the turbocharger exhaust bends. the first mounting bracket for the exhaust system downstream of the catalytic converter from the body. the front SIPS member from the body. the brake pipe from the holders on the SIPS member. Press the exhaust system back so that there is 6070 mm of play at the branching downstream after the

2 2(16) turbocharger. Hint: Use a mobile jack with universal plate as a support. the gaskets. Seal the openings at the exhaust system. Removing components the cross stay between the suspension turrets. plastic pipes, intake/charge air over the engine. upper coolant hose engine/radiator. solenoid valve (turbo control) from the air cleaner. the air cleaner inlet pipe from the connection on the front cover plate. the air cleaner assembly. Relieve the load from the belt tensioner. the auxiliaries belt. First remove the upper timing cover and then the front timing cover. the cover over the ignition coils. Draining the fuel line Drain the fuel line. See Draining the fuel system. Removing the fuel rail the brake vacuum hose from the intake manifold. the charge air pipe from the throttle body (electronic throttle module). the dipstick tube from the intake manifold. the pipe screw for the crankcase ventilation connection at the intake manifold. the vacuum hose from the charge air bypass valve the rear screw in the lower row from the connection between the intake manifold and the cylinder head; remove the bracket. the protective cover over the nozzle connectors. the fuel rail mounting screws. Spray universal oil or similar around the injector connectors on the intake manifold. Gently work the fuel rail and injectors loose. Separate the fuel line quickrelease connector under the intake manifold. Use tool Carefully put the fuel rail to one side.

3 3(16) the EVAP valve hose from the intake manifold Removing components the camshaft position (CMP) sensor housing and the trigger wheel. the pipe screw for the waterheated crankcase ventilation. the clamps for ignition coil wiring and the positive cable. the cover at the rear of the intake camshaft. Removing components from turbo 1 from turbo 1 the ground strips between the engine and the firewall. intake and charge air pipes, plug the openings. the heat deflector plate. the pipe screw for the oil pressure pipe. the oil pressure pipe. the pipe screws for the coolant pipes. Note! Place a receptacle underneath for coolant. the upper coolant pipe with hose. Removing components from turbo 2 from turbo 2 the heat deflector plate. the ground strips between the engine and the firewall. the upper screw of the automatic transmission dipstick tube. Loosen the lower. the torque arm bracket. intake and charge air pipes, plug the openings. the hose from the pressure regulator. the clamp between the coolant pump inlet pipe and the turbocharger oil pressure pipe. Removing components Raise the car and remove the oil return line of turbo 1. Plug the opening in the engine block. the hose from the pressure regulator.

4 4(16) Lower the car and remove the pipe screws of the coolant pipes at turbo 2. Put the lower pipe to one side. the upper coolant pipe and hose to turbo 2. the air control pipe of the pressure regulator. the nuts and washers of the manifold mounting at cylinders 1, 2 and 3. Lift away the manifold/turbocharger. from turbo 2 the screws of the oil return line. Turn the pipe to the side. the pipe screw of the oil pressure pipe. the nuts and washers at the manifold mounting to the cylinder head, cylinders 4, 5 and 6. Lift off and carefully turn the turbocharger/manifold so the oil pressure pipe is released. Note! Exercise extreme care so that the oil pressure pipe is not deformed. Lift up and remove the turbocharger/manifold. Releasing the coolant pump inlet pipe the screw that holds the coolant pump inlet pipe onto the cylinder block. the two screws for the connector between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

5 5(16) Setting up the engine the nuts from the cover on the wing liner. Position the upper timing cover. Turn the crankshaft clockwise until the markings on the crankshaft and camshafts align. the upper timing cover. Removing components the connector for the variable valve timing solenoid. the connector for the coolant temperature sensor. the screws for the ignition coils and the two ground terminals. Lift up and place the ignition coils and wiring to one side. Note! Mark up the ignition coils before removal. Removing the timing belt Slacken off the centre screw for the belt tensioner slightly. Hold the center screw in a fixed position. Turn the tensioner eccentric counterclockwise to 10 o'clock. Use a 6 mm Allen key. the timing belt.

6 6(16) Removing the timing gear pulley tool at the rear of the camshafts. the variable valve timing unit center plug. variable valve timing unit center screw. Pull / pry off the variable valve timing unit and timing belt pulley. screws holding the timing belt (without the variable valve timing unit) to the camshaft. the timing belt pulley. tool Removing the thermostat housing the screw for the thermostat housing cable duct. the screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct. the screw holding the inner timing cover to the cylinder head. Removing the camshaft cover/cylinder head spark plugs for cylinders 2 and 5. tool (x2). Leave a 23 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened. Variable valve timing solenoid. the screws holding the camshaft cover to the cylinder head.

7 7(16) Use pliers to lift the cover from the cylinder head. the pliers at the stop lugs. Start with cylinder 1 and work alternately backward. Slacken off the wing nuts approximately 2 turns. Repeat the procedure with the pliers. Carefully press out the front and rear camshaft seals. the seals. tools the camshaft cover. the camshafts Lift out the valve lifters. Use a suction cup. Caution! Mark up and position the lifters so that their original positions can be established. the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center (see illustration). Get help to lift off the cylinder head. Note! Exercise extreme care so that the mating surfaces are not damaged.

8 8(16) When replacing/machining the cylinder head the intake manifold and gasket. the coolant outlet pipe. Cleaning Cleaning the gasket faces Clean the gasket faces for: the manifold. Check that the studs are tightened. the coolant bypass channel the coolant outlet pipe. intake manifold. engine block. camshaft cover. Blow the oil ducts clean. Note! Use a razor blade or a plastic scraper and gasket solvent Use a fume hood or extractor when using gasket solvent! ing the cylinder head gasket Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct. Tightening For tightening torques not in the text see Tightening torque. Aligning the crankshaft the mounting screws for the starter motor. Pull out the starter motor and place to one side. the blind cover plug. Turn the crankshaft clockwise slightly. the crankshaft stop Ensure that it bottoms out against the engine block. Turn the crankshaft counterclockwise until it stops against the crankshaft stop. Check that the marking on the crankshaft timing belt pulley aligns with the marking on the oil pump. ing the cylinder head a new cylinder head gasket. the cylinder head. Use new screws. Lubricate and install all the screws. Tighten the screws in the order illustrated. Tighten the screws in the following order Nm.

9 9(16) Nm. 3. Angle tighten 130. Use bevel protractor ing valve lifters and camshafts When installing a new cylinder head, the valve clearance must be set. See Valve clearance, setting / adjusting. Lubricate the valve guide wells. all valve lifters Caution! Make sure that the lifters are in the same position as before. Lubricate the camshaft bearing seats. the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line. Applying liquid gasket new Orings around the spark plug wells at the cylinder head. Apply liquid gasket to the camshaft cover. The surface must be completely covered without any excess. Use roller Note! Ensure that no liquid gasket gets into the oil ducts. ing the camshaft covers Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters. the camshaft cover. press tool (2x). Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with the press tools. all the screws and tighten. the variable valve timing solenoid with a new gasket. the press tools.

10 10(16) the spark plugs. Tighten to 30 Nm. ing the rear camshaft seal Use drift Lubricate the surface of the seal that the camshaft rotates against. Press in the seal until the drift bottoms out. Note! If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm by turning the drift socket. Securing the camshafts Use camshaft tool Separate the camshaft adjustment tool into two units. Note! The camshafts must not be turned more than indicated in the text below. This could damage the valves! the exhaust camshaft section of the adjustment tool. Screw into the rear edge of the camshaft. Carefully turn the camshaft adjustment tool clockwise (as viewed from the back of the engine) until the camshaft adjustment tool is parallel with the join between the cylinder head and camshaft cover. the intake camshaft section of the adjustment tool. Screw into the rear edge of the camshaft. Carefully turn the camshaft adjustment tool counterclockwise until it is in contact with the exhaust camshaft section of the camshaft adjustment tool. Screw the adjustment tool sections together into one. Check that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened. ing the front camshaft seal Use drift for camshaft with variable valve timing unit and drift for camshaft without variable valve

11 11(16) timing unit. Lubricate the surface of the seal that the camshaft rotates against. Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out. ing the thermostat housing the screw holding the inner timing cover to the cylinder head. the thermostat housing and cable duct. Use a new gasket the screw for the thermostat housing cable duct. Checking the variable valve timing (VVT) unit Check the variable valve timing unit. See: Variable valve timing unit, checking and adjusting. ing components the trigger wheel. the camshaft position sensor housing, lower screw only. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm. the cover at the rear edge of the intake camshaft. ignition coils using previous markings. the connector for the coolant temperature sensor. the connector for the variable valve timing solenoid. the screws for the 2 ground terminals between ignition coils 1 and 2 and 5 and 6.

12 12(16) below the intake manifold the starter motor. the throttle body connector to the engine wiring. the charge air pipe to the throttle body. Tighten the clamp. the control hose to the charge air bypass valve. the brake vacuum hose to the intake manifold. the bracket and screw to the lower row of screws at the mounting for the intake manifold on the cylinder head. the pipe screws at the underside of the intake pipe for the water heated crankcase ventilation. Tighten to 26 Nm. the dipstick tube to the intake manifold. ing the fuel rail the fuel rail. Use new screws. Tighten to 10 Nm. Press the quickrelease connector for the fuel pressure line until there is an audible click. the clamps holding the injector wiring and the positive cable to the rear edge of the cylinder head. the protective cover over the nozzle connectors. the upper coolant hose to the cylinder head/radiator. Tighten the clamp. ing the coolant pump intake pipe Note! Apply thread sealant to the screws. the coolant pump intake pipe to the cylinder head. Use a new gasket. the screw for mounting the coolant pump intake pipe to the cylinder block.

13 13(16) ing the manifold/turbo 2 new gaskets. Lubricate the studs at the exhaust ports and at the flange on the turbocharger exhaust bend with paste Lower and install the manifold/turbocharger. washers and new nuts that hold the manifold to the cylinder head. the pipe screw holding the oil pressure pipe to the turbocharger. Use new sealing washers. Do not tighten! ing the manifold/turbo 1 new gaskets. Lubricate the studs at the exhaust ports and at the flange on the turbocharger exhaust bend with paste Lower and turn the manifold/turbocharger so that the oil pressure pipe is correctly positioned. washers and new nuts that hold the manifold to the cylinder head. the pipe for pressure regulator control. the upper screw of the camshaft position sensor housing. the upper coolant pipe and hose to turbo 2. Use new sealing washers. Tighten to 26 Nm. the upper coolant pipe and hose to turbo 1. Use new sealing washers. Tighten to 26 Nm. ing components to turbo 1 Raise the car and install the oil return pipe using a new gasket and sealing ring.

14 14(16) Note! First remove the seal from the hole. Thoroughly check that the pipe and sealing ring are correctly positioned. the hose to the pressure regulator. the oil pressure pipe. the pipe screw to the oil pressure pipe connection to the engine block. Use new sealing washers. Do not tighten! the lower coolant pipe. Use new sealing washers. Tighter to 26 Nm. ing components to turbo 2 Lower the car. Tighten the pipe screw of the oil pressure pipe to 18 Nm. the charge air pipe. Position and tighten the clamp. the intake pipe. Position and tighten the clamp. Note! previously installed seals. the torque rod bracket. the upper screw securing the automatic transmission dipstick tube to the engine. Tighten the lower screw. the heat deflector plate above the turbocharger. the ground cable between the firewall and the torque rod bracket. the clamp between the coolant pump intake pipe and the turbocharger oil pressure pipe. ing components to turbo 1 the pipe screw of the oil pressure pipe; use new sealing washers. Tighten to 18 Nm. the heat deflector plate above the turbocharger. the charge air pipe. Position and tighten the clamp. the intake pipe. but do not tighten the clamp. Note! previously installed seals. the ground strips between the right frame member and the cylinder head. ing components the cable duct on the inside of the right suspension turret. the front timing cover. the expansion tank. Connect the connector to the coolant level sensor. the hose to the expansion tank from the radiator.

15 15(16) Secure the clamp and remove the lock grip pliers. Connect the connector to the ABS sensor. servo reservoir. Ensure that the hoses are correctly positioned. the upper timing cover. the cover over the ignition coils. the plastic intake pipe over the engine. Adjust and tighten the intake pipe at the turbocharger. Tighten the clamps and mounting screws on the plastic pipe. the plastic charge air pipe over the engine. Tighten the clamps and mounting screws. the hose between the charge air cooler and the plastic charge air pipe over the engine. Tighten the clamps. the crankcase ventilation hose to the PTC resistor in the plastic intake pipe over the engine. Use a new clamp. the connector for the PTC resistor. the protective cover over the PTC resistor. the EVAP valve hose to the plastic intake pipe. the bypass valve outlet hose to the plastic intake pipe. Tighten the clamp. the air cleaner assembly. Press the air cleaner intake pipe into the front plate port. the plastic intake pipe to the mass air flow sensor. Tighten the clamp. the connector to the mass air flow sensor. Clamp the wiring at the front edge of the air cleaner. the turbocharger control valve to the mounting on the air cleaner the bluemarked hose/turbocharger control system to the intake manifold. the redmarked hose/turbocharger control system to the charge air pipe. the yellowmarked hose/turbocharger control system to the pressure regulators. the cross stay between the suspension turrets the suspension turret covers. Clamp the servo hose to the right mounting on the cross stay. Exhaust system assembly Raise the car. the seals at the exhaust system flanges.

16 16(16) new gaskets. Lift and press the exhaust system against the connection at the turbocharger exhaust bends. Note! Use a mobile jack with universal plate as a support. the screws holding the front SIPS member and rear mounting on the body. Do not tighten! the mobile jack. new nuts at the exhaust gas system connection to the turbocharger. Tighten the nuts at the exhaust system branching and the screws at the front and rear SIPS member. ing components Tighten the pipe screw of the oil pressure pipes to 38 Nm. the drive shaft bearing seat. the right drive shaft. See: Half shaft, right, replacing. the wheels. See: ing wheels. the battery negative lead. Also read Note when disconnecting/connecting the battery lead. Checking and filling media Change the oil and replace the oil filter as necessary. Check the engine oil level. the servo oil level. the coolant level. Warm up the engine until the thermostat opens. Check the engine for leaks. the fluid level in the transmission. the coolant level. Top up as necessary.

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