Overhaul

Assembly overview
Engines with steel plate cylinder head gasket

Engines with aluminium plate cylinder head gasket

Engines with steel plate cylinder head gasket

1 - Cap
^ Replace seal if damaged

2 - Seal
^ Replace if damaged

3 - Breather housing
^ Turn to right to remove

4 - 10 Nm

5 - Seal
^ Replace if damaged

6 - Bracket

7 - Sealing plug, 15 Nm
^ Replace

8 - Seal
^ Replace

9 - Union

10 - Lifting eye

11 - 20 Nm

12 - Cylinder head gasket
^ Replace
^ After replacing, replace entire amount of coolant

13 - 15 Nm

14 - Rear toothed belt guard

15 - Cylinder head
^ Check for distortion.
^ After replacing, replace entire amount of coolant

16 - Cylinder head bolt
^ Replace
^ Remove and install polydrive cylinder head bolt with T10070

17 - Oil deflector

18 - Cylinder head cover gasket
^ Replace if damaged
^ Before installing, seal transitions between bearing cap and cylinder head with D 454 300 A2

19 - Cylinder head cover

20 - Reinforcement strips

21 - Rear toothed belt guard - upper part

Checking cylinder head for distortion

Special tools, testers and auxiliary items required
^ Straight edge
^ Feeler gauges

Max. permissible distortion: 0.1 mm
(Minimum distance between straight edge positions: 100 mm)

Engines with aluminium plate cylinder head gasket

1 - Cap
^ Replace seal if damaged

2 - Seal
^ Replace if damaged

3 - 10 Nm

4 - To intake hose
^ Only applies to engine codes BDC and BGD to Positive Crankcase Ventilation (PCV) heating element -N79-

5 - Shaped hose
^ For engine code AEG as well as engine codes AVH and AZG until model year 2001

6 - Shaped hose
^ For engine codes BDC, BEV, BGD as well as engine codes AVH and AZG from model year 2002
^ Do not separate connection between shaped hose and intake hose

7 - To intake manifold - upper part
^ Only from model year 2002

8 - Seal
^ Replace

9 - Sealing plug, 15 Nm
^ Replace

10 - Cylinder head bolt
^ Replace
^ Remove and install polydrive cylinder head bolt with T10070

11 - Union

12 - 10 Nm

13 - Seal
^ Replace

14 - 20 Nm

15 - Lifting eye

16 - Cylinder head gasket
^ Replace
^ After replacing, replace entire amount of coolant

17 - 15 Nm

18 - 20 Nm

19 - Rear toothed belt guard

20 - Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink.

21 - Cylinder head
^ Check for distortion.
^ After replacing, replace entire amount of coolant

22 - Oil deflector

23 - Cylinder head cover gasket
^ Replace if damaged
^ Before installing, seal transitions between bearing cap and cylinder head with D 454 300 A2

24 - Cylinder head cover
^ With cable guide