Cylinder Head/Gasket, Removing
Cylinder head/gasket, removingSpecial tools: 999 7107 999 7103 999 5454, 999 5670, 999 5452, 999 5433
Note: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparations
Removal of parts
Remove:
- the cover from the expansion vessel
- the batteries earth cable according to: Note when disconnecting/connecting the battery lead
- the right front wheel
- the screws on the right-hand wing liner, move the wing liner backwards.
Drain the coolant
Lift up the vehicle and remove the protective casing under the engine. Open the nipple on the engine. Drain the coolant into a clean collection tray. Close the nipple.
Removing
Removing the Air Cleaner Module (ACL)
Remove the Air Cleaner Module (ACL) according to: Air cleaner (ACL) module, replacing
Mounting of engine
Note: Ensure that no coolant escapes.
Lift up the expansion vessel and place it on the engine. Attach the lifting brace. Use: 999 7103 and tension the tool.
Removal of parts
Remove:
- the screws (1) on the movement limiter for the engine bracket on the right-hand frame side member
- movement limiter
- the screws (2) to the engine bracket on the cylinder head
- the engine mount.
Removal of belt protection covers
Remove:
- the screw to the front belt protection cover
- the front belt protection covers.
Removing the upper intake manifold
Remove:
- the screws to the upper intake manifold, 6, closest to the front plate and the screws opposite the bulkhead, 2
- canister hose from the intake manifold
- the brake vacuum pipe, by pressing in the red catch and pulling out the pipe. Disconnect the connector to the shutter housing and pressure sensor on the intake manifold. Cut off the cable tie on the cable harness to the pressure sensor. Put the intake manifold to one side.
Removal of ignition coils
Remove:
- the ignition coil's mounting screws and screws by the 2 earth points
- the screws to the cable conduit at the rear of the cylinder head.
Disconnect the connector to:
- Variable valve timing solenoid.
- camshaft sensor
Lift up and move the ignition coils and cables to one side
Removing injectors
Disconnect the connector for the injection valves and the connect for the fuel pressure sensor in the fuel rail. Drain the fuel system. See Fuel system draining
Removing the injectors, continued
Remove:
- the fuel rail mounting screws.
- the screw for the clamp on the fuel pressure pipe.
Blow down the injectors. Spray with universal oil or the like around the injector's connection on the inlet manifold. Pull off, without bending, the fuel rail and injectors.
Separate the quick coupling on the fuel pipe by pressing in the two blue plastic catches. Lift out the fuel rail.
Removing the lower intake manifold
Remove:
- screws on the top row to the intake. Loosen the screws on the lower row a few turns. Lift up the intake manifold and loosen the hose between the oil trap and the intake manifold.
- gasket and discard it.
Removing parts at the rear of the engine
Remove:
- screws, 2, to the lifting eye at the rear of the cylinder head
- the screw on the clamp for the fuel pressure pipe in the lifting eye. Unhook the EVAP valve from the lifting eye.
Disconnect the connector to the lambda sonds and move the lifting eye to one side. Loosen the bleeder hose at the rear of the cylinder head.
Removing the rotor on the camshaft
Note: Clear up any oil spillage using paper.
Remove:
- cover at the rear of the camshaft. Use a screwdriver and press in the middle of the cover and pry off the cover.
- screw to the rotor
- rotor.
Removing the feed line to the steering servo pump
Caution: Seal the openings.
Note: Clear up any oil spillage under the delivery line.
Loosen the feed line from the steering servo pump.
Removing the oscillation damper
Remove the screws, 4. Use the centre nut on the camshaft as a counterhold. Fit the counterhold. Use: 999 5433 and remove the centre nut. Remove the counterhold 999 5433.Bend/pull off the oscillation damper.
Adjustment of engine
Loosen the centre screw on the belt tensioner a little. Keep the centre screw locked and turn the eccentric on the tensioner using a hex key (6 mm) clockwise to the 10 o'clock position. Remove the camshaft belt from the camshaft pulley
Installing the camshaft adjustment tool
Use: 999 5452.
Install:
- the part of the tool the belongs to the exhaust camshaft (drilled hole).
- the gauge belonging to the intake camshaft (threaded hole). Screw together the gauges into a single unit.
Removing the Camshaft belt pulley/Variable valve timing unit
Remove:
- plug at the front of the variable valve timing unit
- Note: Use paper to collect any spilled oil under the variable valve timing units.
Centre screw in the variable valve timing unit. Carefully pull out the pulley with the variable valve timing unit.
- screws to the camshaft belt pulley
- the cam belt pulley.
Removing parts exhaust side
Remove the nuts by the partition between the catalytic converter and the exhaust system. Hang the catalytic converter from the rubber suspension and separate the catalytic converter and exhaust system. Lower the vehicle.
Removal of exhaust manifold
Remove:
- the screws to the thermal protection plate on the exhaust manifold, 5. Let the plate lie loose on the exhaust manifold.
- Note: Use rust solvent or similar on the studs. the nuts to the exhaust manifold against the cylinder head. Lift off and place the exhaust manifold on the water pipe.
Removal of the camshaft cover
Remove:
- the variable valve timing (VVT) solenoid
- the spark plugs on cylinder 2 and 4. Fit the tool. Use: 999 5454 with 2-3 mm clearance to the camshaft cover. Make sure that the screw in the spark plug thread is tightened to the bottom and that the screws hold the camshaft cover to the cylinder head.
Use a pair of pliers: 999 5670 to lift the cover from the cylinder head. Use the pliers on the lugs. Start by cylinder 1 and move crosswise and backwards. Loosen the wing nuts about 2 turns and repeat the procedure.
Removing the front camshaft seal
Note: Exercise care so that the contact faces on the camshaft are not damaged.
Carefully push off the front camshaft seals.
Removing the cam follower
Note: Mark up and position the lifters so that their original positions can be established.
Remove:
- tools 999 5454 and 999 xxx
- the camshaft cover
- the camshafts Lift out the lifters. Use a magnet or suction cup.
Mounting of engine
Remove the bracket for the oil pipe to the steering servo. Fit tool 999 7107 with the screws to the bracket for the steering servo.
Removing the front engine bracket
Remove:
- lifting brace 999 7103
- the screws to the front engine bracket on the cylinder head, 3 at the front and 2 on the intake side.
- the front engine bracket
- the screw to the inner belt protection cover on the cylinder head.
Removing the cylinder head
Note: Do not damage the mating surfaces.
Remove the screws holding the cylinder head on the engine block. Start at the sides and move crosswise in towards the middle. Get a colleague to assist, and lift off the cylinder head.