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Front cylinder head, to remove (in car)

Front cylinder head, to remove (in car)


1. Drape the wing protectors over the wings and remove the engine cover.


2. Disconnect the negative cable from the battery.

3. Open the cap on the expansion tank and release the pressure.

4. Raise the car.

5. Remove the bottom engine cover.


6. Drain the coolant from the radiator.

7. Remove the turbo bracket, minding the protective plate for the crankshaft position sensor mounted on the same bracket.

8. Insert two 83 95 238 Wedges , between the oil sump and subframe and between the gearbox and subframe.


9. Lower the car.

10. Remove the mass air flow sensor with hose.


11. Detach the power steering hose from the holder.

12. Remove the right-hand engine attachment with bracket and engine mount.

13. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley


14. Release the multigroove belt from tension.

15. Remove the coolant pump pulley and power steering pump pulley.

16. Remove the belt tensioner and generator air intake.

17. Remove the timing cover.

18. Unhook the throttle cable.


19. Remove the vacuum hoses and unplug the pressure sensor's connector from the upper intake manifold.

20. Detach the vacuum hose and the two water hoses from the throttle. Remove the turbo pressure hose with charge air bypass pipe. Unplug the throttle's connector and detach the venting-valve hose from the underside of the throttle.

21. Unplug the connectors from the ignition discharge module and injectors.


22. Detach the fuel lines.

23. Undo the upper intake manifold and move it aside.

24. Remove the middle intake manifold.


25. Remove the lower intake manifold. Plug the holes with paper or the like.

26. Undo the coolant bridge and move it aside. Mind the gaskets.

27. Remove the crankshaft pulley.

28. Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use Installation tool for camshaft sprockets and camshaft drive belt KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets.


29. Undo the tensioning pulley and adjusting rollers. Use tool 83 94 983 as a counterstay on the adjusting rollers.


30. Mark the direction of rotation on the belt. The belt can also be marked with the respective camshaft markings and crankshaft marking to facilitate refitting. Remove tool KM-800-10 from the crankshaft. Let locking tools KM-800-1 and KM-800-2 remain. Remove the lower adjusting roller. Ensure the washer behind the roller is also removed. Remove the timing belt.

31. Remove the bracket with tensioning roller and the upper adjuster roller.


32. Remove the ignition discharge module.


33. Remove the camshaft cover. Make sure that the O-rings are in place and that they do not fall into the engine.

34. Rotate the crankshaft to 60° BTDC. Note the marking.


35. Remove the camshaft sprockets.

Warning

The jaws of the open-ended spanner used as a counterstay when removing the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.


36. Remove the coolant pump.

37. Remove the inner timing cover.

38. Remove the front exhaust manifold's heat shield.


39. Detach the crankcase breather pipe from the turbo intake pipe. Note the gasket. Move the pipe aside.

40. Remove the turbo intake pipe. Also detach the hose connected to the venting valve.

41. Detach the hose between the turbo and charge air cooler.

42. Detach the water hose from the thermostat housing.


43. Detach the front exhaust manifold from the turbo.

44. Remove the turbo's water pipes.

45. Remove the turbo's oil pipes.

46. Undo and remove the exhaust camshaft. Undo the bolts in stages, 1/2 to 1 turn at a time. Note the marking on the bearing caps.


It is important to finish removal at the bearing cap where the tappets are under load.

Remove the stuffing box.

Note

The intake camshaft need not be removed.


47. Remove the tappets with the 83 91 401 Magnetic tool . Keep the tappets in the 83 93 787 Valve rack

48. Undo the cylinder head bolts in the order shown. First slacken them a 1/4 turn and then 1/2 a turn. Remove the cylinder head. Be careful when putting it down as the intake camshaft is still in place and the valve stems could be bent accidentally.