Front cylinder head (in car)
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Front cylinder head (in car)
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Warning
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Removal of the fuel rail involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:
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Make sure a class BE fire extinguisher is close to hand! Consider the risk of sparking, e.g. when breaking circuits, short-circuits etc.
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Absolutely No Smoking!
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Ensure that there is a good exchange of air. If approved ventilation for the extraction of fuel fumes is available, this should be used.
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Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
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Wear protective goggles.
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Important
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Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.
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1.
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Undo the cap on the expansion tank.
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2.
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Raise the car and remove the lower engine cover.
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3.
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Slowly and carefully relieve the tension of the belt tensioner. Remove the multigroove V-belt. Mark the belt's direction of rotation for refitting.
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4.
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Place a suitable receptacle under the car and drain the cooling system.
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5.
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Undo the front bolt on the front torque arm.
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6.
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Disconnect the charge air pipe from the charge air cooler.
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7.
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Undo the bolt from the dipstick.
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8.
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Lower the car and remove the intake manifold with mass air flow sensor from the turbocharger.
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9.
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Remove the upper engine cover and charge air hose with pipe from the upper intake manifold.
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10.
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Remove the upper radiator hose.
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11.
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Detach the connector and cable tie from the dipstick. Remove the dipstick.
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12.
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Remove the lower bolt and remove the upper bolt securing the lifting eye. Move aside the lifting eye.
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13.
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Unplug the connectors and remove the fan cowling.
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14.
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Undo the lower bolt and remove the lifting eye.
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15.
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Remove the nut on the rear engine mounting.
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16.
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Undo the quick-release couplings on the fuel lines. Use a cloth to catch any fuel spill.
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17.
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Take up the weight of the engine using a jack. Remove the right-hand engine mounting with the bracket and engine pad. Raise the engine slightly and remove the engine bracket bolts.
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18.
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Remove the timing belt cover.
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19.
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Zero the engine, aligning the crankshaft pulley, camshaft pulleys and fuel pump pulley with the markings on the engine.
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20.
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If the markings on the belt are unclear, remark the belt to correspond with the marks on the pulleys.
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21.
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Insert a 6 mm drill bit or similar into the hole in the tensioner pulley and turn it slowly and carefully to relieve the pressure. Remove the tensioner pulley by undoing the bolt and simultaneously withdrawing the pulley.
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22.
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Remove the timing belt and idler pulley.
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23.
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Remove the power steering pump with bracket.
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24.
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Unplug the connectors, remove the front cable rail and move aside the engine harness.
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25.
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Remove the upper intake manifold and the turbocharger's bracket.
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26.
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Remove the fuel pipes and fuel rail. Put the spacer washer from under the fuel rail's hexagon-headed bolt in a safe place.
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27.
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Remove the heat shield from over the exhaust manifold as well as the turbocharger heat shield.
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28.
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Remove the bolts between the exhaust manifold and the turbocharger pipes.
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29.
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Remove the camshaft cover.
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Warning
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Release the pressure in the fuel system before starting work. Cover the fuel connections with a rag to protect against spurting fuel.
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30.
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Detach the fuel feed pipe from its mounting and from the fuel return connection. Undo the banjo connection in the rear of the camshaft holder frame. Remove the injector holders.
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31.
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Remove the injectors and the fuel return pipes.
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32.
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Remove one bolt in the cover at the timing belt gear.
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33.
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Remove the studs securing the holders to the injectors. Remove the camshaft holder frame.
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34.
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Remove the bolts securing the water-cooled EGR pipe against the intake manifold and loosen the water jacket pipe clips.
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35.
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Remove the bolts holding the crankshaft ventilation pipe against the front bank's intake manifold.
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36.
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Remove the bolts from the coolant pipe against the cylinder head.
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37.
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Remove the cylinder head.
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1.
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Clean the sealing surfaces and the combustion chamber. Blow the bolt holes clean using compressed air. Make sure that the guide rings are correctly positioned in the cylinder block.
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2.
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Fit the cylinder head using a new gasket and new bolts. Note the different bolt lengths. Check that the gasket has correct graduation as illustrated. Tighten the bolts following the order below (L=front cylinder bank)
Tightening torque, short bolts
Step I: 39 Nm (29 lbf ft)
Step II: Tighten a further 110°
Step III: Tighten a further 110°
Tightening torque, long bolts
Step I: 39 Nm (29 lbf ft)
Step II: Tighten a further 130°
Step III: Tighten a further 130°
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3.
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Fit the bolts holding the crankshaft ventilation pipe against the front bank's intake manifold.
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4.
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Remove the bolts securing the water-cooled EGR pipe against the intake manifold. Tighten the pipe clips.
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5.
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Fit the coolant pipes using new seals against the cylinder head.
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6.
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Clean the sealing surfaces and make sure the holes are free from oil. Fit the camshaft holder frame using a new gasket and bolts in the order illustrated.
Tightening torque: 25 Nm (18 lbf ft)
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7.
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Fit the studs securing the injector holders.
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8.
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Fit the bolt in the cover at the timing belt gear.
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9.
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Fit the injectors using new seals.
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10.
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Fit the fuel return pipes on the injectors. Make sure that the double sealing washer does not stick out and get caught against the camshaft cover sealing surface.
Tightening torque: 20 Nm (15 lbf ft)
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11.
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Fit the injector holders. make sure the holder goes down in the injector slot. Tighten the nuts evenly.
Tightening torque, small nuts 5 Nm (4 lbf ft)
Tightening torque, large nuts 29 Nm (21 lbf ft)
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12.
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Fit the fuel feed pipe against the mounting and fuel return connection in the camshaft holder frame using new seals.
Tightening torque: 20 Nm (15 lbf ft)
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13.
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Fit the camshaft cover using new seals as described under
Replacing camshaft cover seals
. Apply a bead of silicon flange sealant, part no. 87 81 841, on the outer portion of the camshaft cover as illustrated.
Tightening torque: 8 Nm (6 lbf ft)
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14.
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Fit the bolts between the exhaust manifold and the exhaust pipe. Fit the heat shields over the exhaust manifold and the turbocharger. Apply Molycote 1000 to the bolts.
Tightening torque: 25 Nm (19 lbf ft)
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15.
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Fit the catalytic converter. Apply Molycote 1000 to the studs.
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16.
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Plug in the fuel pressure sensor connector. Make sure that the protective sock is fitted.
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17.
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Fit the fuel rail and fuel pipe using new seals. Make sure that the spacer washer is fitted under the fuel rail.
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18.
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Fit the upper intake manifold and the turbo bracket. Use new gaskets for the intake manifold and the EGR pipe.
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19.
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Fit the engine wiring harness and plug in its connectors.
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20.
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Fit the power steering pump with bracket.
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21.
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Fit the bolt to the delivery pipe holder and the cable tie to the engine harness wiring.
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22.
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Fit the lower bolt to the front lifting eye.
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23.
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Fit the dipstick bolt using a new O-ring. Secure the cable of the oil pressure switch to the dipstick pipe using a cable tie.
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24.
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If the belt tensioner has been triggered, slowly and carefully relieve the tension in a vice and fit the locking pin. Fit the belt tensioner. Position the belt so that the markings align with the belt pulleys. Fit the idler pulleys and remove the locking pin.
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25.
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Turn over the engine twice and check that the markings on the pulleys are aligned with those in the covers.
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26.
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Fit the upper timing belt cover.
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27.
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Fit the quick-release couplings on the fuel lines.
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28.
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Fit the right-hand engine mounting with bracket and engine pad. Raise the engine slightly to insert the engine bracket bolts.
Tightening torque: 47 Nm (35 lbf ft)
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29.
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Lower the engine and remove the jack. Fit the nut to the right-hand engine mounting.
Tightening torque: 47 Nm (35 lbf ft)
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30.
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Fit the nut of the rear engine pad.
Tightening torque: 47 Nm (35 lbf ft)
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31.
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Move aside the lifting eye and fit the fan cowling.
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32.
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Fit the upper bolt securing the lifting eye and secure the dipstick pipe to the lifting eye.
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Important
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To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
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33.
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Plug in the connectors to the fans. Fit the upper radiator hose and the charge air hose with pipe to the upper intake manifold.
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34.
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Refit the upper engine cover.
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35.
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Fit the intake manifold with mass air flow sensor. Plug in the mass air flow sensor connector.
Tightening torque, mass air flow sensor: 3.5 Nm (2.5 lbf ft)
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36.
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Raise the car and tighten the bolt securing the dipstick pipe.
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37.
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Slowly and carefully relieve the tension on the belt tensioner and fit the multigroove V-belt.
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38.
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Fit the front bolt to the torque arm.
Tightening torque: 90 Nm + 90° (66 lbf ft + 90°)
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39.
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Fit the charge air pipe to the charge air cooler.
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40.
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Fit the lower engine cover and lower the car.
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