Cylinder head (in situ)
Cylinder head (in situ) |
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To remove |
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Important | ||
Always use wing covers when working in the engine bay. |
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1. |
Remove
Timing belt (in situ)
.
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3. |
Loosen the coolant expansion tank cap to release any pressure.
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4. |
Raise the car and position plastic wedges or the like between the drive shaft and subframe as well as between the A/C compressor bracket and subframe.
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5. |
Place a suitable receptacle under the radiator, attach a hose to the radiator and drain the coolant. Close the cock and fit the cover.
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6. |
Remove the front exhaust pipe.
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7. |
Detach the turbocharger oil return pipe from the engine block.
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8. |
Remove the lower nuts and bolts from the turbocharger heat shield.
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9. |
Slightly loosen the lower mounting of the front catalytic converter.
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10. |
Lower the car and remove the lifting beam.
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11. |
Detach the EGR valve connector.
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12. |
Detach the vacuum pipes from the camshaft housing and vacuum tank.
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13. |
Remove the nuts from the radiator pipe holder on the starter motor bracket.
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14. |
Detach the turbocharger delivery hose from the pipe and throttle body.
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15. |
Remove the turbocharger intake manifold. Plug the connections.
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16. |
Remove the bolt securing the dipstick guide tube.
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17. |
Remove the brake vacuum hose.
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18. |
Unplug the connector of the coolant temp. sensor.
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19. |
Detach the expansion tank bleeder hose.
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20. |
Remove the crankcase ventilation hose from the clip. Move the hose aside.
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21. |
Detach the lower radiator hose from the coolant pipe.
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22. |
Detach the upper radiator hose from the thermostat housing.
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23. |
Detach the coolant hoses from the coolant pipe.
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24. |
Detach the hoses from the thermostat housing.
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25. |
Slightly slacken the bolt securing the turbo inlet pipe's upper retaining bracket.
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26. |
Detach the EGR pipe between the exhaust manifold and heat exchanger.
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27. |
Remove the heat shield.
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28. |
Remove the exhaust manifold nuts and move it forward so that the studs are accessible.
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29. |
Detach the return fuel pipe from the return fuel tank.
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30. |
Detach the fuel hose from the high pressure pump.
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31. |
Detach the wiring harness from the crankcase ventilation pipe. Remove the bolts holding the pipe in place and move it aside.
Cars with preheated crankcase ventilation:
Cut the cable tie and remove the brackets.
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32. |
Unplug the following connectors:
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32.a. |
Mass air flow sensor connector. (686)
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32.b. |
Wiring harness connector. Fit bracket and cable tie.
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32.c. |
A/C compressor connector (170).
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32.d. |
Front temperature sensor (602).
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32.e. |
Camshaft position sensor (555).
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32.f. |
Injectors (206).
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32.g. |
Fuel pressure sensor (653).
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32.h. |
Fuel pressure solenoid valve (652a).
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32.i. |
Electronic throttle actuator (604).
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32.j. |
Intake air sensor (688).
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32.k. |
Glow plug connector (398).
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33. |
Remove the retaining bolts of the cable duct and move the wiring harness aside.
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34. |
Remove the vacuum reservoir.
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35. |
Remove the nuts and bolts holding the oil trap bracket in place and move it aside.
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36. |
Remove the combustion circulation actuator. Carefully bend the control arm from the ball coupling.
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37. |
Detach the fuel delivery pipe between the pump and fuel rail.
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38. |
Remove the injector (206)
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39. |
Remove the fuel rail and hose.
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40. |
Remove the bolt between the fuel pump bracket and cylinder head. Slacken the spacer bolt a few turns.
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41. |
Loosen and remove the camshaft shaft housing and the guide sleeves. Remove in alternating order as illustrated.
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42. |
Remove the cylinder head by undoing the bolts in the order illustrated.
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43. |
Carefully lift off the cylinder head.
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44. |
Remove the engine block guide sleeves.
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To fit |
1. |
Clean the bolt holes in the cylinder block.
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2. |
Clean away any gasket residue from the sealing surfaces of the cylinder head and cylinder block.
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3. |
Use a steel rule to check that the cylinder head and cylinder block are flat and the sealing surfaces are not damaged.
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4. |
Position the guide sleeves on the cylinder block.
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5. |
Position a new gasket with the same thickness as the old one.
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6. |
Fit the cylinder head to the cylinder block.
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7. |
Tighten the cylinder head bolts in the order illustrated.
Tightening torques Step I: 65 Nm (48 lbf ft) Step II: +90° Step III: +90° Step IV: +90° |
8. |
Clean away any gasket residue from the sealing surfaces of the cylinder head and camshaft housing.
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9. |
Fit the guide sleeves and position a new gasket on the cylinder head.
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10. |
Fit the camshaft housing, tightening the bolts alternatingly. Check that the guide sleeves are properly positioned in the camshaft housing.
Tightening torque: 25 Nm (18 lbf ft) |
11. |
Screw in the spacer sleeve to the cylinder head and fit the bolt.
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12. |
Fit the fuel rail and hose.
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13. |
Fit the injector (206)
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14. |
Fit the fuel delivery pipe between the pump and fuel rail.
Tightening torque: 25 Nm (18 lbf ft) |
15. |
Fit the combustion circulation actuator and attach the control arm to the ball coupling.
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16. |
Fit the nuts and bolts holding the oil trap bracket in place.
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17. |
Fit the vacuum reservoir.
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18. |
Fit the wiring harness and cable duct retaining bolts.
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19. |
Reposition the engine harness and plug in the following connectors:
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19.a. |
Front temperature sensor (602).
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19.b. |
Camshaft position sensor (555)
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19.c. |
Injectors (206).
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19.d. |
Fuel pressure sensor (653).
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19.e. |
Fuel pressure solenoid valve (652a).
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19.f. |
Throttle body actuator (604)
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19.g. |
Sensor, intake air (688)
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19.h. |
Glow plug connector (398).
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19.i. |
Mass air flow sensor connector. (686)
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19.j. |
A/C compressor connector (170).
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19.k. |
Wiring harness connector. Fit bracket and cable tie.
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20. |
Cars with preheated crankcase ventilation:
Fit the brackets.
All:
Fit the bolts of the crankcase ventilation pipe. Fit the wiring harness.
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21. |
Attach the fuel hose to the high pressure pump.
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22. |
Attach the return fuel pipe to the return fuel tank.
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23. |
Fit the exhaust manifold nuts and move it forward so that the studs are accessible. Use a new gasket.
Tightening torque: 20 Nm (15 lbf ft) |
24. |
Fit the upper bolts of the heat shield.
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25. |
Attach the EGR pipe between the exhaust manifold and the heat exchanger. Use new gaskets.
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26. |
Tighten the bolt securing the turbo inlet pipe's upper retaining bracket.
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27. |
Attach the hoses to the thermostat housing.
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28. |
Attach the coolant hoses to the coolant pipe.
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29. |
Attach the upper radiator hose to the thermostat housing.
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30. |
Attach the lower radiator hose to the coolant pipe.
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31. |
Fit the crankcase ventilation hose to the clip.
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32. |
Fit the expansion tank bleeder hose.
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33. |
Plug in the connector of the coolant temp. sensor.
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34. |
Attach the brake vacuum hose.
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35. |
Fit the bolt securing the dipstick guide tube.
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36. |
Remove the plugs and attach the turbocharger intake manifold.
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37. |
Attach the turbocharger delivery hose to the pipe and throttle body.
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38. |
Fit the nuts from the radiator pipe holder on the starter motor bracket.
Tightening torque: 10 Nm (7 lbf ft) |
39. |
Attach the vacuum pipes to the camshaft housing and vacuum tank.
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40. |
Attach the EGR valve connector.
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41. |
Raise the car.
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42. |
Tighten the lower mounting of the front catalytic converter.
Tightening torque: 25 Nm (18 lbf ft) |
43. |
Fit the lower nuts and bolts of the turbocharger heat shield.
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44. |
Attach the turbocharger oil return pipe to the cylinder block.
Tightening torque: 20 Nm (15 lbf ft) |
45. |
Attach the front exhaust pipe using new gaskets.
Tightening torque: 25 Nm (18 lbf ft) |
46. |
Connect the negative battery cable.
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47. |
Fit
Timing belt (in situ)
.
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48. |
Pressure test - see Cooling system, pressure testing - and fill coolant - see Filling and bleeding cooling system.
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49. |
Carry out
Procedure after battery disconnection
.
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50. |
Check and clear any diagnostic trouble codes using the diagnostic tool.
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