Table of contents: Removal ↓ Installation ↓
Removal
Drain the coolant. Remove the intake manifold. Set the crankshaft to "TDC" and secure the camshafts with the "T10016" camshaft lock. Put the "10.222 A" crossmember with the "10.222 A/10" hook and the "10.222 A/11" spindle on the front fender flanges, as shown in the figure. The lead screws are at the rear. Hang the "hook snap hook" 10.222 A/10- on the right engine eye. The "10.222 A/11" spindle will be used later. Remove the camshaft housing.
Warning! Risk of injury from high-pressure fuel. When releasing residual pressure, place a clean cloth around the connection and carefully disconnect.
Remove fuel hoses "1" and "3". Remove hose "2" from the absorber. Do not take into account the "arrow". Unscrew the bolts of the "arrow" and remove the heat shield.
Unscrew the "arrow" nut for the exhaust manifold bracket.
Unscrew the nuts "arrows" of the pre-catalyst connection on the exhaust manifold. Remove the bracket of the exhaust manifold.
Disconnect the "arrow" connector of the oil pressure sensor "F1".
Unscrew bolt "1" for the bracket on the oil radiator for the supply and return lines of the coolant and remove it with the mounting bracket. Ignore the "arrows".
Unscrew the thermostat housing arrow bolts.
Disconnect connectors "1. 2, 3" and "arrows", freely lay the wiring harness on the cylinder head.
Unscrew bolts "1" and loosen bolt "2". Lightly press the vacuum actuator for the intake manifold flap back.
Unscrew the bolt "arrow" and remove the running roller "1" for the main drive toothed belt.
Unscrew the "arrow" bolts and remove the rear cover "1" of the toothed belt.
Screw the bracket "T10014", as shown in the figure, with a torque of 40 Nm into the threaded hole in the cylinder block.
Hang the spindle "10.222 A/11" with the additional hook "10.222 A/2" on the right on the holder "T10014". Create pre-tension with both lead screws, disconnect the additional hook "10.222 A/10" and move it to the side. Loosen the cylinder head bolts in the sequence -1. 10. Unscrew the bolts and carefully remove the cylinder head. Place the cylinder head on a soft lining (foam).
Installation
Caution! Risk of damage to the sealing surface. Carefully remove any remaining sealant from the cylinder head and cylinder block. Avoid the formation of long scratches or scoring. Risk of damage to the cylinder block. There must be no oil or coolant in the blind holes of the cylinder head mounting bolts. Risk of a leaky cylinder head gasket. During repairs, carefully remove any remaining sealant from the cylinder head and cylinder block. Avoid the formation of long scratches or scoring. Carefully remove any remaining emery and sanding material. Remove the new cylinder head gasket from the packaging immediately before installation. Handle the gasket with particular care to prevent damage to the silicone layer and the grooves of the cylinder head 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 is in direct contact with the cylinder head. Replace bolts that were tightened further. Replace self-locking nuts, lip seals, gaskets and O-rings. Replace the mesh oil filter in the cylinder head. Before installing the exchange cylinder head, it is necessary to lubricate the adjacent surfaces of the hydraulic compensators, rocker arms and working surfaces of the cams with oil before installing the camshaft bearing housing. Secure all hose connections with 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 open engine parts.
Remove any remaining sealant from the cylinder head and camshaft housing. Clean the mounting surfaces; they should be free of oil and grease.
Check the TDC position of the camshaft: the flattened tooth on the toothed belt gear "1" for the crankshaft must match the "arrow" mark on the oil pump housing. Ignore pos. "2". Turn the crankshaft back in the direction opposite to the direction of engine rotation by approximately 45°. Install the seal for the thermostat housing. Install the cylinder head gasket. Watch the dowel pins on the cylinder block. Installation position of the cylinder head gasket: the "top" mark or the part number must be clearly legible. Install the cylinder head.
Tighten the cylinder head bolts. After performing repair work, do not tighten the cylinder head bolts. Install in the reverse order, while it is necessary to install the rear cover for the toothed belt. Install the running roller for the main drive toothed belt. Install the vacuum regulator of the intake manifold flap. Install the thermostat housing. Install the bracket for the exhaust manifold and heat shield. Install the camshaft housing. Install the toothed belt for the main drive. Install the intake manifold. Change the oil. Change the coolant.