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Cylinder head (in situ)

Cylinder head (in situ)

Warning

The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


To remove

Warning

Diesel under high pressure! So wait for at least one minute after switching off the engine before starting work in the fuel system. Diesel fumes are explosive and can cause severe burn injuries.


Important

Always use wing covers when working in the engine bay.



1. Remove Timing belt (in situ) .

2. Disconnect the negative cable from the battery.

Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



3. Loosen the coolant expansion tank cap to release any pressure.

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.


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.

6. Remove the front exhaust pipe.


7. Detach the turbocharger oil return pipe from the engine block.

8. Remove the lower nuts and bolts from the turbocharger heat shield.


9. Slightly loosen the lower mounting of the front catalytic converter.

10. Lower the car and remove the lifting beam.

11. Detach the EGR valve connector.


12. Detach the vacuum pipes from the camshaft housing and vacuum tank.


13. Remove the nuts from the radiator pipe holder on the starter motor bracket.


14. Detach the turbocharger delivery hose from the pipe and throttle body.


15. Remove the turbocharger intake manifold. Plug the connections.


16. Remove the bolt securing the dipstick guide tube.

17. Remove the brake vacuum hose.


18. Unplug the connector of the coolant temp. sensor.

19. Detach the expansion tank bleeder hose.

20. Remove the crankcase ventilation hose from the clip. Move the hose aside.

21. Detach the lower radiator hose from the coolant pipe.


22. Detach the upper radiator hose from the thermostat housing.

23. Detach the coolant hoses from the coolant pipe.

24. Detach the hoses from the thermostat housing.

25. Slightly slacken the bolt securing the turbo inlet pipe's upper retaining bracket.


26. Detach the EGR pipe between the exhaust manifold and heat exchanger.

27. Remove the heat shield.

28. Remove the exhaust manifold nuts and move it forward so that the studs are accessible.


29. Detach the return fuel pipe from the return fuel tank.


30. Detach the fuel hose from the high pressure pump.

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.

32. Unplug the following connectors:

32.a. Mass air flow sensor connector. (686)

32.b. Wiring harness connector. Fit bracket and cable tie.


32.c. A/C compressor connector (170).

32.d. Front temperature sensor (602).

32.e. Camshaft position sensor (555).


32.f. Injectors (206).

32.g. Fuel pressure sensor (653).

32.h. Fuel pressure solenoid valve (652a).

32.i. Electronic throttle actuator (604).

32.j. Intake air sensor (688).

32.k. Glow plug connector (398).

33. Remove the retaining bolts of the cable duct and move the wiring harness aside.

34. Remove the vacuum reservoir.


35. Remove the nuts and bolts holding the oil trap bracket in place and move it aside.

36. Remove the combustion circulation actuator. Carefully bend the control arm from the ball coupling.


37. Detach the fuel delivery pipe between the pump and fuel rail.

Important

If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.



38. Remove the injector (206)

39. Remove the fuel rail and hose.


40. Remove the bolt between the fuel pump bracket and cylinder head. Slacken the spacer bolt a few turns.


41. Loosen and remove the camshaft shaft housing and the guide sleeves. Remove in alternating order as illustrated.

42. Remove the cylinder head by undoing the bolts in the order illustrated.


43. Carefully lift off the cylinder head.

Important

Do not confuse the engine block guide sleeves with the camshaft guide sleeves.


44. Remove the engine block guide sleeves.


To fit


1. Clean the bolt holes in the cylinder block.

2. Clean away any gasket residue from the sealing surfaces of the cylinder head and cylinder block.

3. Use a steel rule to check that the cylinder head and cylinder block are flat and the sealing surfaces are not damaged.

Important

Do not confuse the engine block guide sleeves with the camshaft guide sleeves.


4. Position the guide sleeves on the cylinder block.


5. Position a new gasket with the same thickness as the old one.

6. Fit the cylinder head to the cylinder block.

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.

9. Fit the guide sleeves and position a new gasket on the cylinder head.

Note

Check that all rocker arms are properly positioned on the valve stem.




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.


12. Fit the fuel rail and hose.


13. Fit the injector (206)


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.


16. Fit the nuts and bolts holding the oil trap bracket in place.


17. Fit the vacuum reservoir.

18. Fit the wiring harness and cable duct retaining bolts.

19. Reposition the engine harness and plug in the following connectors:

19.a. Front temperature sensor (602).

19.b. Camshaft position sensor (555)


19.c. Injectors (206).

19.d. Fuel pressure sensor (653).

19.e. Fuel pressure solenoid valve (652a).

19.f. Throttle body actuator (604)

19.g. Sensor, intake air (688)

19.h. Glow plug connector (398).

19.i. Mass air flow sensor connector. (686)


19.j. A/C compressor connector (170).

19.k. Wiring harness connector. Fit bracket and cable tie.

20. Cars with preheated crankcase ventilation: Fit the brackets. All: Fit the bolts of the crankcase ventilation pipe. Fit the wiring harness.


21. Attach the fuel hose to the high pressure pump.

22. Attach the return fuel pipe to the return fuel tank.

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.


25. Attach the EGR pipe between the exhaust manifold and the heat exchanger. Use new gaskets.

26. Tighten the bolt securing the turbo inlet pipe's upper retaining bracket.

27. Attach the hoses to the thermostat housing.


28. Attach the coolant hoses to the coolant pipe.

29. Attach the upper radiator hose to the thermostat housing.

30. Attach the lower radiator hose to the coolant pipe.

31. Fit the crankcase ventilation hose to the clip.


32. Fit the expansion tank bleeder hose.

33. Plug in the connector of the coolant temp. sensor.

34. Attach the brake vacuum hose.

35. Fit the bolt securing the dipstick guide tube.


36. Remove the plugs and attach the turbocharger intake manifold.

37. Attach the turbocharger delivery hose to the pipe and throttle body.


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.


40. Attach the EGR valve connector.


41. Raise the car.

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.

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.

47. Fit Timing belt (in situ) .

48. Pressure test - see Cooling system, pressure testing - and fill coolant - see Filling and bleeding cooling system.

49. Carry out Procedure after battery disconnection .

50. Check and clear any diagnostic trouble codes using the diagnostic tool.