Removal and Replacement

Right Cylinder Head:

Left Cylinder Head:

NOTE: Take off cylinder head together with camshafts and exhaust manifold only after engine has cooled down.

1. Raise hood to vertical position.
2. Disconnect ground cable at battery.
3. Drain coolant at crankcase, refer to Cooling System.
4. Remove poly V-belt refer to Replacement. Service and Repair





5. Left cylinder head: unscrew bolts (arrows), then detach mounting plate with power steering pump (11) from tensioning device and place to the side With lines/wiring connected.

Installation Note: The bolt which is screwed into the cylinder head from the front must be coated with sealant when installed. Pay attention to angle bracket (1) of wiring harness.

6. Right Cylinder Head: unbolt alternator from bracket and place to the sides with wiring connected and secure.
7. Remove cylinder head (valve) covers. Service and Repair
8. Remove "front cover at top" of cylinder head to be taken off. Service and Repair





9. Rotate engine so that cylinder 1 is at 45° before ignition TDC.





10. Mark all four camshaft sprockets and the timing chain with colored dots (arrows).

Installation Note: Examine and adjust basic setting of camshafts.

11. Remove chain tensioner. Service and Repair
12. Remove top guide rails. Service and Repair
13. Unbolt exhaust camshaft sprockets and camshaft timing adjusters at the cylinder head to be removed. Service and Repair
14. Remove intake manifold.
15. Left Cylinder Head: detach coolant hose at the rear.
16. Right Cylinder Head: unbolt dipstick guide tube at rear of automatic transmission.
17. Unbolt exhaust system at the cylinder to be removed at exhaust manifold. Exhaust System
18. Detach exhaust system at transmission bracket.
19. Right Cylinder Head: unbolt wiring harness at bottom right





20. Unscrew bolts + washers (a), (b), (c), (d), (e), (f) of cylinder head to be removed.





21. With engine cold, loosen cylinder head bolts at the cylinder head to be removed:
- Proceed in stages in reverse order of tightening diagram
- Beginning with bolt 10.
- Use wrench insert (1), tool No. 119 589 00 10 00





22. Install bracket tool No 119 589 01 40 00 at the cylinder heads to be removed. To do this, unbolt second and fourth camshaft bearing caps of the inlet camshaft at the right and left cylinder head, respectively, and install bracket with dowel sleeves (18a).
23. Attach engine hoist to bracket, raise cylinder heads and remove.

CAUTION: Do not damage guide rails and pay attention to exhaust manifold.

24. Examine cylinder head contact surface, reface as required. Checking/Refacing Cylinder Head Contact Surface
25. Clean tapped holes of cylinder head bolts, ensure they are free of oil and water.
26. Replace cylinder head gaskets.

NOTE: The cylinder head gasket is not watertight until the engine has reached normal operating temperature, in other words until a swelling process has taken place. For this reason, the cooling system must not be pressure-tested until after the engine has reached normal operating temperature.
Pay attention to dowel sleeves or roll pins for locating cylinder head in position on crankcase.





27. Examine cylinder head bolts. The cylinder head bolts are subject to a permanent stretch each time they are tightened. If the maximum length of is reached or exceeded before re-using, replace the bolts with new ones.
28. Oil the thread of the cylinder head bolts and the contact surface of the bolt heads and insert.
29. Tighten cylinder head bolts in stages in the order of the tightening diagram, beginning with 1. See Tightening Specifications. Specifications
30. Install remaining components in the reverse order.