Removal and Replacement

Removing and installing cylinder head

Proceeding work

Front cover at top removed. Refer to Timing Components - Timing Cover - Service and Repair - Procedures Service and Repair
Resonance intake manifold top part removed. Refer to Intake Manifold - Service and Repair - Procedures Service and Repair

Replacement

NOTE: Take off cylinder head together with camshafts, intake manifold and exhaust manifold once engine has cooled down.
Seal secondary air injection hole at right side on cylinder heads for engines without secondary air injection hole with end cover part no. 104 016 00 33







1. Unbolt front exhaust system (10) at exhaust manifold.
2. If secondary air injection fitted, detach secondary air injection hose (3).
3. Unbolt bracket (4) with spacer sleeve (5) at secondary air injection pipe (6).
4. Drain coolant at crankcase.
5. If equipped with automatic transmission, unbolt dipstick guide tube (8) at rear right of cylinder head.
6. Take off coolant hose (9) at rear of cylinder head.
7. Position of camshaft sprockets relative to timing chain. Mark timing chain with colored dots (arrows).

Note: Fit timing chain unto colored markings (arrows)






8. Unbolt exhaust camshaft sprocket (76).
9. Take off timing chain of inlet camshaft sprocket.
10. Slacken cylinder head bolts (9) together with washers (9a). Slacken when engine is cold with tool No. 617 589 00 10 00, in stages in reverse order of tightening diagram beginning with bolt 14.

11. Unbolt first camshaft bearing cap (13) of exhaust camshaft.
12. Install bracket 104 589 00 40 00 in place of first camshaft bearing cap (13) with bearing cap bolts (13a).
13. Attach engine hoist to bracket (3) and rear engine lifting point.
14. Lift cylinder head (10).

15. Examine cylinder head contact surface.
16. Clean tapped holes.

CAUTION: To prevent damage when tightening bolts, ensure tapped holes are free of oil and water.

17. Replace cylinder head gasket (11).

NOTE: The cylinder head gasket (11) for engine 104.941 is identified with three recesses (arrows).

CAUTION: The cylinder head gasket is not watertight until the engine has reached operating temperature, in other words, until a swelling operation has taken place. For this reason, the cooling system must not be pressure tested until after the engine has reached operating temperature


18. Install cylinder head (11).
19. Note position of cylinder head alignment dowel sleeves (12).

20. Examine cylinder head bolts (9).
Length of cylinder head bolts:
New: 160 mm
Maximum: 163.5 mm

21. Oil cylinder head bolt (9) threads and at bolt head contact surface.
22. Insert cylinder head bolts (9) with washers (9a).

23. Tighten cylinder head bolts in stages in order of tightening diagram, beginning with bolt 1.
1st stage, tighten to: 55 Nm
2nd stage, turn an additional 90°
3rd stage, turn an additional 90°

24. Reverse procedure to install.

Torque camshaft bearing caps to 21 Nm.
Fit timing chain onto colored markings (arrows).