Cylinder head, removing and fitting

Unscrew the lid on the oil filler connection

2x Unscrew

Screw on the lid on the oil filler connection

Pull off the cable set connector (2) - Heating conductor-mass air flow sensor

Undo the cable set (arrows)

Detach the engine ventilation hose (3)

Detach the intake hose (4)

5x Undo bolt

5x Undo bolt

Turn the multi-belt tension device in the direction of the arrow-

Use KM-913-A or a 15mm flex-head spanner (2)

Insert KM-6130 or a 4.5mm drift (1)

Mark the direction of rotation

Tighten the multi-belt tension device

Remove KM-6130 (2) or drift.

Undo the multi-belt tension device

Undo the bolt (1)

Prise loose the front screw plug from the oil pan

Use KM-911 ( 83 96 327 Holder tool, fixing of flywheel )

Undo the bolt

Remove KM-911

Important: When removing the middle silencer, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the components of the exhaust system remaining on the car must be supported to stop them hanging. The exhaust system component with the flexible pipe can be fastened to the underbody using a suitable object, e.g. steel wire. If the flexible pipe bends 5 - 10 degrees from its intended mounting position there may be damage caused and complete failure of the flexible pipe.

Remove the front exhaust pipe - 3x Unscrew nut

Instruction: 2 technicians are needed

Undo the exhaust system.

3x Pull off cable set connector - Oil pressure switch (1), crankshaft sensor (2), dynamic oil level check sensor (3)

Undo the cable set

Undo the screw at the top

Undo the screw at the bottom

Undo the nut

3x Unscrew (1)

Detach from the rear tooth belt cover

Undo the bolt (arrow)

Detach from the rear tooth belt cover

2x Unscrew

Unscrew the nut from the fuel line holder

Unscrew the stud

Pull off the camshaft sensor cable set connector (1) - Undo the cable set connector

Set the crankshaft to the mark - Turn the crankshaft at a steady rate.

Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond (III)

Fix the camshaft sprockets.

Instruction: The markings must be in line with each other and correspond with the top of the cylinder head (I) - Use KM-852 (II)

Undo the tooth belt tensioning pulley (IV) - Undo the bolt - Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer(1) on the tooth belt tensioning pulley is just short of the left-hand end position.

Undo the bolt

Place a receptacle underneath

Open the drain screw (arrow)

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.

Use 83 94 744 Adapter, fuel pressure gauge

Unscrew the test connector protective collar

on the fuel rail

from the fuel rail

Use 83 95 261 Fuel line tool

Remove the engine vent hose - Undo the clamp

13x Pull off the cable set connector - Air conditioning pressure sensor (10), compressor (9), coolant temperature sensor (8), fuel evaporation valve, throttle valve module (1), solenoid valve switch throttle, 2x engine control modules (2), knock sensor (3), combination connector (4), lambda sensor, fuel regulator (7), DIS ignition module (6).

Remove the nozzles' cable duct - Undo the bolt

Remove the ground cable.

Remove the cable set

5x Undo bolt

Remove the DIS ignition module

Use KM-6009 ( 83 96 335 Removal tool, ignition discharge module Z18XE ) (1)

Instruction: Do not pull out crooked

5x Undo bolt

Remove the DIS ignition module - Use KM-6009 (83 96 335 Removal tool, ignition discharge module Z18XE) (1)

Instruction: Do not pull out crooked

Remove the throttle valve module preheating line-

2x Undo bolt -

Undo the clamp

Undo the cable set for the fuel regulation lambda sensor

10x Undo bolt

Remove the seal

Use KM-796-A.

Undo the generator

Undo the bolt

Swing back the generator

Undo the bolt - Hold the camshaft hexagon

Undo the bolt - Hold the camshaft hexagon

2x Unscrew

from the intake manifold

Undo the holder

From intake manifold

Remove the throttle valve preheating return hose - Undo the clamp

7x Undo the bolt (arrows)

Remove the seal

Undo the bolt

2x Detach the clamp from the coolant connection(1), coolant pump (2)

from the thermostat housing

Undo the clamp

3x Unscrew

10x Unscrew nut - Remove the engine transport bracket

Remove the seal

Remove the cable set holder - Undo the bolt

Undo the bolt

10x Undo bolt.

Instruction: Undo the bolts in the illustrated order - Undo bolts (90°) - Undo bolts (180°)

Important: Place the cylinder head on suitable wood blocks

Remove the cylinder head gasket

cylinder head, engine block, exhaust manifold, intake manifold, camshaft cover

Important: The cylinder head must not be refaced.

Measure the height of the cylinder head with a steel rule and feeler gauge - Sealing surface to sealing surface: 135.85 - 136 mm (dim l)

Put on the cylinder head gasket Instruction: OBEN / TOP must be face up

Instruction: 2 technicians are needed

Instruction: Change the cylinder head bolts

10x Screw the cylinder head bolt tight

10x Tighten cylinder head bolt - Tightening torque 25 Nm + 90° + 90° + 90° + 45°

Instruction: Observe the tightening order!

Fit the cable set holder - Tighten the bolt - Tightening torque 8 Nm

Tighten the bolt - Tightening torque 8 Nm

Change the seal

10x Change nut

Put in place the engine transport bracket

Important: The nuts must be torque tightened twice in tightening order

10x Tighten nut - Tightening torque 12 Nm + 12 Nm

Instruction: Observe the tightening order!

3x Tighten bolt - Tightening torque 8 Nm

Fasten the clamp

2x Fasten clamp - On coolant connection, coolant pump - Tighten the bolt - Tightening torque 60 Nm

7x Tighten nut - Tightening torque 20 Nm

Fit the throttle valve preheating return hose - Fasten the clamp

Instruction: The connection should make an audible click

2x Tighten bolt - Tightening torque 6 Nm

Change the bolt

Tighten the bolt - Tightening torque 50 Nm + 60° + 15° - Hold the camshaft hexagon

Instruction: 2. A technician is needed

Change the bolt

Tighten the bolt - Tightening torque 50 Nm + 60° + 15° - Hold the camshaft hexagon

Instruction: 2. Technicians are needed

Instruction: The markings must be in front of each other and correspond with the top edge of the cylinder head.

Use KM-852 - Turn the camshafts with the hexagon

Important: Complete the assembly work within 10 minutes

Change the seal (2)

Apply sealant (1)

10x Tighten bolt - Tightening torque 8 Nm

Fit the throttle valve module preheating line - 2x Tighten bolt - Tightening torque 8 Nm - Fasten the clamp

Fasten the cable set for the fuel regulator lambda sensor

Unscrew KM-6009

5x Tighten bolt - Tightening torque 8 Nm

13x Fasten cable set connector - Air conditioning pressure sensor, compressor, coolant temperature sensor, fuel evaporation valve, throttle valve module, solenoid valve switch throttle, engine control module, combination connector, fuel regulator lambda sensor, DIS ignition module

Fit the nozzle cable duct - Tighten the bolt - Tightening torque 8 Nm

Fit the engine vent hose - Fasten the clamp

Fit the ground cable.

Tighten the nut - Tightening torque 15 Nm

Tighten the bolt - Tightening torque 20 Nm

Tighten the bolt - Tightening torque 25 Nm

Put the crankshaft on the mark - Turn the crankshaft at a steady rate Instruction: The marks on the tooth belt sprocket and tooth belt cover must correspond.

Tension the tooth belt tensioning pulley - Turn the setting eccenter in the direction of the arrow (anticlockwise) until the pointer on the tooth belt tension roller is just short of the right-hand end position

Fasten the bolt for the tooth belt tensioning pulley (1)

Turn the crankshaft (720°) - on the bolt for the crankshaft multi-belt pulley

Instruction: in the direction of rotation of the engine

Put the crankshaft on the mark

Instruction: The markings on the tooth belt pulley and rear tooth belt cover must correspond

Put in KM-852

Instruction: The markings must be in front of each other and correspond with the top edge of the cylinder head.

Undo the tooth belt tensioning pulley - Undo the bolt

Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer (1) on the tooth belt tensioning pulley corresponds with the groove (2) - Adjust a used tooth belt to the USED mark - Adjust a new tooth belt to the NEW mark

Tighten the bolt for the tooth belt tensioning pulley - Tightening torque 20 Nm

Turn the crankshaft (720°)

Instruction: The pointer on the tooth belt tensioning pulley and the groove must agree-

Adjust a used tooth belt to the USED mark -

Adjust a new tooth belt to the NEW mark

2x Clean threads - For camshaft sensor

Instruction: Fit the bolts with locking compound (red)

2x Tighten bolt - Tightening torque 8 Nm

Fasten the cable set connector - Fasten the camshaft sensor cable set connector

Tighten the stud - Tightening torque 15 Nm

Tighten the nut - Tightening torque 15 Nm - From the fuel line holder

Fasten the rear tooth belt cover

Tighten the bolt - Tightening torque 4 Nm

Fasten the rear tooth belt cover

3x Tighten bolt - Tightening torque 4 Nm

Tighten the nut - Tightening torque 35 Nm

3x Fasten the cable set connector - Oil pressure switch, crankshaft sensor, dynamic oil level sensor

Fasten the cable set

on the intake manifold - Tighten the bolt - Tightening torque 20 Nm

on the engine block - Tighten the bolt - Tightening torque 35 Nm

Instruction: 2 technicians are needed

Instruction: Change the seal

3x Change nut

3x Tighten nut - Tightening torque 25 Nm

Tighten the bolt - Tightening torque 35 Nm

Tension the multi-belt tensioning device - Use KM-913-A

Put in KM-6130

Use KM-911

Change the bolt

Tighten the bolt - Tightening torque 95 Nm + 30° + 15°

Remove KM-911

Put in the screw plug

Instruction: Observe the rotation direction and fitting position

Undo the multi-belt tensioning device - Use KM-913-A

Remove KM-6130

Place a receptacle underneath

Unscrew the oil drain screw

Place a receptacle underneath

Use KM-726-A

Tighten the oil filter - Use KM-726-A - Tightening torque 15 Nm

Change the sealing ring - Tightening torque 14 Nm

Fit the intake hose

Fit the engine vent hose

Connect cable set connector

Fasten the cable set

Unscrew the lid on the oil filler connection

2x Tighten bolt - Tightening torque 8 Nm

Screw on the lid on the oil filler connection

Observe the prescribed engine oil and coolant volumes

Start the engine and allow it to run until the oil pressure control display goes out.

Check the engine oil level and top up as necessary.

Instruction: Fill and bleed the cooling system - see procedure Bleeding the cooling system .