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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. Note the radio code where applicable. Detach the vent hose and remove the battery.

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

4. Raise the car.

5. Remove the lower 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. Detach the turbocharger delivery pipe from the charge air cooler, leave on the clamp. 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 body. Remove the turbocharger delivery pipe. Remove the turbocharger delivery pipe with bypass pipe and valve from the throttle body and unplug the connector for the pressure/temp sensor. Unplug the throttle body connector and detach the purge valve hose from underneath the throttle body.

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 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 Fitting set.


29. Detach the tensioning pulley and the adjuster roller. Remove the guide roller. Use 83 94 983 Adjustment wrench, timing belt, V6 as counterstay on the adjuster rollers.


30. Mark the direction of rotation on the item to be refitted. In order to facilitate fitting the belt can be marked with each camshaft marking as well as with the crankshaft marking. Remove the tool KM-800-10 from the crankshaft. Remove the camshaft belt.

31. Undo the adjuster roller bolts.


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 heat shield.


39. Undo the hose connection to the front SAI valve by pressing together the clip and pulling back.

40. Remove the SAI pipe with valve from the exhaust manifold

41. Undo the crankshaft ventilation pipe between the turbo intake pipe and the cylinder head as well as the hose from the oil trap. Bend aside the pipe.

42. Undo the turbo intake pipe. Bend aside the pipe.

43. Detach the turbo's outlet hose to the charge air cooler.

44. Detach the water hose from the thermostat housing.


45. Detach the front exhaust manifold from the turbo.

46. Remove the turbo water pipe.

47. Remove the turbo's oil pipes.

48. 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.


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

50. 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.