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Rear cylinder head, to remove (in car)

Rear cylinder head, to remove (in car)


1. Cover the wings and remove the engine cover. Remove the battery cover.


2. Note the radio code, where applicable, and remove 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 covers.


6. Drain the coolant from the radiator.

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


8. Lower the car.

9. Remove the mass air flow sensor with hose.

10. Detach the power steering hose from the holder.


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

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

13. Release the multigroove belt from tension.


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

15. Remove the belt tensioner and generator air intake.

16. Remove the timing cover.

17. Unhook the throttle cable.

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


19. Detach the oxygen sensor connectors from the holder on the rear SAI valve by releasing the catch and pushing them down.

20. Undo the SAI pipe mounting from the cylinder head. Detach the connections on the exhaust manifold. Undo the hose connection to the SAI valve by pressing together the clip and pulling back.


21. Undo the vacuum hose and the two water hoses from the throttle body. Remove the turbo delivery hose with bypass pipe.


22. Unplug the throttle body connector and detach the hose to the purge valve from underneath the throttle body.

23. Detach the fuel lines.


24. Undo the upper intake manifold and move it aside. Unplug the connectors from the ignition discharge module and injectors.

25. Remove the middle intake manifold.


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

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

28. Remove the crankshaft pulley.

29. Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use tool KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft. See Installation tool for camshaft sprockets and camshaft drive belt


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


31. 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.

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


33. Remove the ignition discharge module.


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

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


36. 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.


37. Remove the coolant pump.

38. Remove the inner timing cover.

39. Raise the car and detach the front exhaust pipe from the rear exhaust manifold.


40. Lower the car. Undo the exhaust camshaft and remove it. Undo the bolts alternately 1/2 to 1 turn. Note the markings on the 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.


41. Remove the tappets with the magnetic tool part no. 83 91 401. Keep the tappets in the 83 93 787 Valve rack

42. 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.