Withdrawal
Drain coolant. Remove intake manifold. Install the crankshaft "TDC" and secure camshafts with camshaft clamp -T10016-. Push cross member -10.222 A- with hook -10.222 A/10- and spindle -10.222 A/11- onto front fender flares as shown in illustration. The lead screws are at the back. Hook the snap hook -10.222 A/10- onto the right engine eye. Spindle -10.222 A/11- will be used later. Remove the camshaft housing.
Detach intake air preheating hose from heat shield -arrow-.
Secure the detachable element against bending with locking pin -T40035-.
Remove bolts -arrows- for front exhaust pipe to exhaust manifold.
Pull connector -arrow- for lambda probe -G39- out of holder and unplug.
Remove bolt -arrow- for bracket for exhaust manifold.
Unplug connector -arrow- for oil pressure sender -F1-.
Remove bolts -arrows- for exhaust manifold pipe.
Disconnect connector -3-. Unscrew nuts -arrows-, remove pipe -1- for exhaust gas recirculation and remove exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212- item. -2-.
Detach coolant hose -5- from thermostat housing.
Unscrew bolts -arrows- for thermostat housing.
Remove throttle valve unit -3338-. Remove bolts -arrows- and move intake manifold back slightly.
Unscrew bolt -arrow- and remove drive pulley -1- for toothed belt of main drive.
Unscrew bolts -arrows- and remove toothed belt rear cover -1-.
Screw bracket -T10014- as shown in illustration to 40 Nm into threaded hole in cylinder block.
Hang spindle -10.222 A/11- with additional hook -10.222 A/2- on holder -T10014- on right. Apply pretension with both spindles, remove additional hook -10.222 A/10- and lay aside.
Loosen cylinder head bolts in sequence 1-10. Unscrew the bolts and carefully remove the cylinder head. Lay the cylinder head on a soft lining (Styrofoam).
Installation
Carefully! Risk of seal damage. surfaces. Carefully remove sealant residue from cylinder head and cylinder block. Avoid long scratches or gouges. Risk of damage to the cylinder block. There must be no oil or coolant in the blind holes of the cylinder head bolts. Risk of leaking cylinder head gasket. When repairing, carefully remove sealant residues from the cylinder head and cylinder block. Avoid long scratches or gouges. Carefully remove the remnants of emery and grinding. A new cylinder head gasket should be removed from the packaging immediately before installation. To prevent damage to the silicone layer and the cylinder head gasket grooves, special care must be taken when handling the gasket. Risk of damage to open valves When installing an exchange cylinder head, remove the plastic base to protect the open valves only when it comes into direct contact with the cylinder head. Replace the bolts that have been tightened further. Replace self-standing nuts, lip seals, gaskets and seals. rings. Replace the oil strainer in the cylinder head. Before installing the exchange cylinder, it is necessary to lubricate the adjacent surfaces of the hydraulic lifters, rocker arms and running surfaces of the cams with oil before installing the body. camshaft bearings. Secure all hose clamps of the appropriate series. After replacing the cylinder head or cylinder head gasket, it is necessary: to completely replace the coolant and oil. Close exposed engine parts.
Remove sealant residues on cylinder head and camshaft housing. Clean the landing surfaces; they must be free of oil and grease.
Check position "TDC" camshaft: The flattened tooth on the toothed belt sprocket -1- for the crankshaft must align with the mark -arrow- on the oil pump housing. Rotate the crankshaft in the opposite direction to the direction of engine rotation by approx. 45°. Lay the seal for the thermostat housing. Install seal for intake manifold. Install the cylinder head seal. Pay attention to the dowel pins on the cylinder block. Cylinder head gasket installation position: Marking "up" or part number should be legible. Install cylinder head. Tighten cylinder head bolts.
Instruction. After carrying out repair work, do not tighten the cylinder head bolts.
Installation is in reverse order, while installing the rear cover for the toothed belt. Install the drive roller for the main drive toothed belt. Install throttle valve unit -J338-. Install the thermostat housing. Install exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212- and pipes for exhaust gas recirculation. Install bracket for exhaust manifold, Install downpipe with catalytic converter. Install the camshaft housing, Install the toothed belt for the main drive. Install intake manifold. Change oil. Replace coolant.
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