Unscrew the bolts -arrows- of the poly V-belt pulley for the power steering impeller pump, to do this use the 2-hole wrench -3212- as a stop.
Remove bolts -1- and -2- and place power steering vane pump aside. -Pos. 3- and -arrow- should not be taken into account.
Disconnect connector -3- from coolant temperature sensor -G62-. Unscrew bolts -1,2,4, 5- of the front coolant pipe.
-Arrows- ignore. Unscrew the nuts -arrows- and remove the protective shield -1- for the high-pressure line.
Unscrew the fastener -2- and remove the fuel supply. highway to the side. Disconnect el. plug connections -1 - and -6-.
-Pos. 4, 3, 5- and -arrows- are ignored. Disconnect the electrical connections on the right and left -arrows- from the timing control actuators. Unscrew bolts -1- and -2- and release wiring harness.
Remove the cylinder head cover: left, right. Disconnect electrical connector -3 for Hall sensor -G40- on right cylinder head. Unscrew the bolt -4 for the ground cable.
-Pos. 1, 2, 5 - ignore. Unscrew the bolts -arrows- and remove the left connector holder. -Pos. 1...4 - do not take into account.
Unscrew the bolts -arrows- and remove the right connector bracket. -Pos. 1...4- do not take into account.
Unscrew bolt -arrow- and remove guide tube for oil dipstick.
Remove the vacuum hose from the vacuum pump by releasing the clamp -arrow-. Release the vacuum hose.
Remove bolts -arrows- behind the cylinder head. Left cylinder head: 3 bolts. Right cylinder head: 4 bolts.
The intake camshaft cams partially obstruct access to the cylinder head bolts, shown as an example -1- and -2-. To remove bolt -1-, the moving part of the camshaft must be pressed using a plastic wedge in -direction of arrow A-. To remove the bolt -2-, the moving part of the camshaft must be pressed using a plastic wedge in -direction of arrow B-. Risk of damage. The moving part of the camshaft can only be moved in the main part of the phase, that is, the lever of the moving part should not be loaded with the force of the cam. Therefore, to loosen the cylinder head bolts, proceed as described below. Otherwise, damage may occur. The moving part of the camshaft must not be moved by thin bridges.
Insert guide pins of adapter -T40058- as shown below: large diameter -arrow 1 - faces engine. The small diameter -arrow 2- faces the adapter.
Turn crankshaft using adapter -T40058- in direction of engine rotation -arrow- until the camshaft position shown in the following illustrations is reached.
The recesses -arrows- on the exhaust camshaft must point towards the outside of the engine, as shown in the illustration.
Left cylinder head: Push the unloaded moving part of the camshaft -B- in the -direction of the arrow- until it stops.
Right cylinder head: Push the unloaded moving part of the camshaft -F- in -direction of the arrow- until it stops.
All
Turn crankshaft using adapter -T40058- in direction of engine rotation arrow - 1 turn. The threaded holes -arrows- in the camshafts must point upwards.
Left cylinder head: Unscrew bolt -1- and remove.
Right cylinder head: Unscrew bolt -2- and remove.
All
Turn crankshaft using adapter -T40058- in direction of engine rotation -arrow- 1 turn. The recesses -arrows- on the exhaust camshaft must point towards the side of the engine.
Left cylinder head: Push the unloaded moving parts of the camshaft -B- and -C- -in the direction of the arrow- until they stop.
Right cylinder head: Push the unloaded moving part of the camshaft -F- in -direction of the arrow- until it stops.
All
Turn crankshaft using adapter -T40058- in direction of engine rotation -arrow- 1 turn. The threaded holes -arrows- in the camshafts must point upwards. Remove the chains from the camshafts. Risk of damage to valves and piston crowns. Even if the chain is removed from only 1 cylinder head, the crankshaft is prohibited from turning.
Left cylinder head: Unscrew and remove bolts -3...9-, to do this, move the unloaded moving part -A- of the camshaft accordingly. Remove the cylinder head.
Right cylinder head: Unscrew and remove bolts -10...16- by moving the unloaded moving parts -D- and -E-camshaft accordingly. Remove the cylinder head.
Installation
Carefully! Risk of damage to the seal. surfaces. Carefully remove any remaining sealant from the cylinder head and cylinder block. Do not allow long scratches or burrs to form. Risk of damage to the cylinder block. There should be no oil or coolant in the blind holes of the cylinder head mounting bolts. Danger of cylinder head gasket leakage. Carefully remove residues after sanding and sanding. The new cylinder head seal should be removed from its packaging immediately before installation. To prevent damage to the silicone layer and the grooves of the cylinder head gasket, the gasket must be handled with extreme care. Risk of damage to open valves. When installing an exchange cylinder head, the plastic base should be removed to protect the open valves only when it is in direct contact with the cylinder head. Risk of damage to valves and piston crowns after working on the valve mechanism. To ensure that no valve comes into contact with the cylinder head during operation, carefully turn the engine at least 2 turns. Replace bolts that were overtightened. Replace self-locking nuts, lip seals, gaskets and seals. rings. Consider different sealants for sealing surfaces and cylinder head bolts. Before installing the exchange cylinder head, it is necessary to lubricate the adjacent surfaces of the hydraulic compensators, rocker arms and the working surface of the cams with oil. Secure all hose connections with hose clamps of the appropriate series. If the cylinder head or cylinder head gasket has been replaced, the coolant and oil must be replaced. Before installing the cylinder head, install the crankshaft and camshafts in "TDC", to do this, install the camshaft clamps -T40133- on both cylinder heads and tighten them to a torque of 25 Nm -arrows-.
The camshaft lock -T40133- is installed correctly if the holes directed towards the cylinder head bolts remain free. The fixing bolt -T40069- must be screwed into the crankshaft.
Apply cylinder head gasket. Pay attention to the centering pins -arrows- in the cylinder block.
Mounting position of the cylinder head seal: marked "top" or the spare part number for the cylinder head. Install the cylinder head.
Left cylinder head: Insert bolts -1...7- by moving the unloaded moving part -A- of the camshaft accordingly. Tighten the bolts in the sequence -1... 7 - in 3 steps.
Right cylinder head: Insert bolts -8...14- by moving the unloaded moving parts -D- and -E- of the camshaft accordingly. Tighten the bolts in sequence -8...14- in 3 steps.
All
Install the drive chains to the camshafts. Remove camshaft clamps -T40133- and securing bolts -T40069-. Turn crankshaft using adapter -T40058- in direction of engine rotation -arrow- 1 turn. The recesses -arrows- on the exhaust camshaft must point towards the side of the engine.
Left cylinder head: Push the unloaded moving parts of the camshaft -B- and -C- -in the direction of the arrow- until they stop.
Right cylinder head: Push the unloaded moving part of the camshaft -F- in -direction of the arrow- until it stops.
All
Turn crankshaft using adapter -T40058- in direction of engine rotation -arrow- 1 turn. The threaded holes -arrows- in the camshafts must point upwards.
Left cylinder head: Insert bolt -15- and tighten it in 3 steps.
Right cylinder head: Insert bolt -16- and tighten it in 3 steps.
All
Turn crankshaft using adapter -T40058- in direction of engine rotation -arrow- 1 turn. The recesses -arrows- on the exhaust camshaft must point towards the side of the engine.
Left cylinder head: Push the unloaded moving part of the camshaft -B- in the -direction of the arrow- until it stops.
Right cylinder head: Push the unloaded moving part of the camshaft -F- in -direction of the arrow- until it stops.
All
Tighten bolts -arrows-. Left cylinder head: 3 bolts. Right cylinder head: 4 bolts.
Do not tighten the cylinder head bolts. Installation is in reverse order, but install the oil dipstick guide tube. Install the drive chains to the camshafts. Install the cylinder head cover: left, right. Install the upper coolant supply pipe. Install the power steering pump. Install an additional muffler. Install fuel discharge hose and lower part of the air intake. Install the poly V-belt. Install the upper coolant pipe. Change the oil. Replace coolant.
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