Removal and Replacement
Cylinder head/gasket, replacing
Special tools:
999 5452 Camshaft Adjustment Tool 999 5452 Camshaft Adjustment Tool
951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)
999 5454 Press Tool 999 5454 Press Tool
999 5670 Pliers 999 5670 Pliers
999 5451 Adjustment Tool 999 5451 Adjustment Tool
951 2050 Bevel Protractor 951 2050 Bevel Protractor
999 5450 Punch 999 5450 Punch
999 5718 Drift 999 5718 Drift
951 2767 Roller 951 2767 Roller
Removal
Preparations
Note! Since 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.
- Disconnect the battery negative lead. First read Battery, disconnecting Battery Disconnecting
- Remove the radiator breather tube at the expansion tank
- Install lock grip pliers
- Install the cover from the expansion tank.
Lift up the servo reservoir and place it on top of the engine.
Note! Make sure that the power steering fluid does not leak from the breather hole in the filler cap.
Seal the hose between the expansion tank and the radiator.
Disconnect the hose at the tank. Lift up the expansion tank and place it on top of engine.
Remove the turbocharger (TC). See Turbocharger (TC), replacing Turbocharger (TC), Replacing.
Removing components
Remove:
- the ground strip between the cylinder head and the engine
- the upper engine coolant hose between the engine and radiator
- the solenoid valve (turbocharger (TC) control system) from the air cleaner (ACL)
- the air cleaner (ACL) intake from the connection on the front cover plate
- air cleaner (ACL) assembly
- torque rod for cross stay
- the upper timing cover
- the cover over the ignition coils
- the front timing cover. See Service and Repair
Relieve the load from the belt tensioner. Remove the auxiliaries belt.
Depressurizing the fuel system
Depressurize the fuel system acc. to Fuel system pressure release Fuel System Pressure Release.
Removing the fuel rail
Remove:
- the brake vacuum hose from the intake manifold
- the charge air pipe from the electronic throttle module
- the dip stick pipe from the intake manifold
- the pipe screw for the crankcase ventilation connection at the intake manifold
- the protective cover over the nozzle connectors
- the fuel rail mounting screws.
Spray universal oil or similar around the injector connectors on the intake manifold. Gently work the fuel rail and injectors loose.
Unplug fuel line's quick-connector under the intake manifold. Use tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298). Carefully put the fuel rail to one side.
Remove the EVAP hose from the intake manifold.
Removing components
Remove:
- the camshaft position (CMP) sensor housing and trigger wheels
- the pipe screw at the rear edge of the cylinder head for the water heated crankcase ventilation
- the clamps for the high tension wiring and positive cable.
Releasing the inlet pipe for the coolant pump
Remove:
- the screw that holds the inlet pipe for the coolant pump on the cylinder block
- the two screws for the connector between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.
Setting up the engine
- Remove the nuts from the cover on the fender liner
- Position the upper timing cover
- Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond
- Remove the upper timing cover.
Removing components
Remove:
- the variable valve timing solenoid connectors
- the connector for the coolant temperature sensor
- the screws for the ignition coils and the two ground terminals.
Note! Mark up the ignition coils before removing.
Lift up and place the ignition coils and wiring to one side.
Removing the timing belt
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock using a (6 mm) Allen key.
Remove the timing belt.
Removing the variable valve timing unit and timing gear pulley
Install tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the rear of the camshafts.
- Remove the center plugs for the variable valve timing units.
Note! Collect oil spills using paper under the plugs
- Remove the variable valve timing unit center screws
- Pull or work off the variable valve timing units and timing gear pulley.
Remove tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
Removing the thermostat housing
Remove:
- the screw for the thermostat housing cable duct
- screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct
- the screw holding the inner timing cover to the cylinder head.
Removing the camshaft cover and cylinder head
- spark plugs for cylinders 2 and 5. Install tool 999 5454 PRESS TOOL 999 5454 Press Tool , 2 pcs., leave a 2-3 mm gap to the camshaft cover. Make sure that the screw in the spark plug well is tightened completely.
- Variable valve timing solenoids
- the screws holding the camshaft cover to the cylinder head.
- Use pliers 999 5670 Pliers 999 5670 Pliers to lift the cover from the cylinder head. Apply the pliers at the stop lugs.
- Start with cylinder 1 and work alternately backward
- Slacken off the wing nuts approximately 2 turns
- Repeat the procedure with the pliers.
Carefully press out the front and rear camshaft seals.
Remove the seals.
Remove:
- tools 999 5454 PRESS TOOL 999 5454 Press Tool
- the camshaft cover
- the camshafts.
Caution! Mark up and position the lifters so that their original positions can be established.
Lift out the valve lifters.
Use a suction cup.
Position the valve lifters on a piece of paper to drain.
- Remove the screws holding the cylinder head on the cylinder block
- Start at the sides and work alternately towards the center (see the illustration)
- Get help to lift off the cylinder head.
Note! Do not damage the mating faces.
When replacing or working on the cylinder head
Remove:
- the intake manifold and gasket
- the coolant outlet pipe.
Installation
Note! For tightening torques, see Specifications, B6324S Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.
Cleaning the gasket faces
Clean the gasket faces for:
- the manifold. Check that the studs are tightened
- the coolant bypass channel
- the coolant outlet pipe
- the intake manifold
- the cylinder block
- camshaft cover.
Blow the oil ducts clean.
Note! Use a razor blade or a plastic gasket scraper and gasket solvent 1161 440. Use a fume hood or extractor when using gasket solvent.
Installing the cylinder head gasket
Caution! Always use new gaskets where the joint has been broken.
Aligning the crankshaft
- Remove the starter motor mounting screws. Pull out the starter motor and place to one side
- Remove the blind cover plug
- Turn the crankshaft slightly clockwise. Install crankshaft stop 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool. Make sure that it bottoms out against the engine block.
- Turn the crankshaft counter-clockwise until it stops against the crankshaft stop
- Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing the cylinder head
Install a new cylinder head gasket.
Install the cylinder head.
Use new screws. Lubricate and install all the screws.
Tighten the screws in the order illustrated. See Tightening torque, B6324S Tightening Torque.
Follow the steps.
Use angle gauge 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Installing valve lifters and camshafts
When installing a new cylinder head, the valve clearance must be set, Valve clearance, setting / adjusting Valve Clearance, Setting/Adjusting.
Caution! Make sure that the lifters are in the same position as before.
Lubricate the valve lifter wells and the lifters. Install all the valve lifters.
Installing the camshafts
- Lubricate the camshaft bearing positions
- Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line
- Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line.
Applying liquid gasket
Note! Make sure that no liquid gasket gets into the oil channels.
- Install new O-rings around the spark plug wells at the cylinder head
- Apply liquid gasket 11 61 059 to the camshaft cover
- Use roller 951 2767 Roller 951 2767 Roller. The surface must be completely covered without any excess.
Installing the camshaft covers
- Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters
- Install the camshaft cover. Install press tool 999 5454 PRESS TOOL 999 5454 Press Tool , 2 pcs.
- Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools
- Install all the screws and tighten
- Install the variable valve timing solenoids using new gaskets
- Remove the press tools
- Install the spark plugs. Tighten. See Tightening torque, B6324S Tightening Torque.
Installing the rear camshaft seals
- Use drift 999 5450 PUNCH 999 5450 Punch.
- Lubricate the surface of the seal that the camshaft rotates against
- Press in the seal until the drift bottoms out.
Note! If there are wear grooves on the camshaft, the seal can be pressed in another 2 mm by reversing the tool's sleeve.
Securing the camshafts
Use camshaft tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
Separate the camshaft adjustment tool into two units.
Caution! The camshafts must not be turned more than is listed in the text below. The valves may be damaged.
- Install the exhaust camshaft section of the adjustment tool
- Screw into the rear edge of the camshaft
- Carefully turn the camshaft adjustment tool clockwise (as viewed from the back of the engine) until the camshaft adjustment tool is parallel with the join between the cylinder head and camshaft cover
- Install the intake camshaft section of the adjustment tool
- Screw into the rear edge of the camshaft
- Carefully turn the camshaft adjustment tool counter-clockwise until it is in contact with the exhaust camshaft section of the camshaft adjustment tool
- Screw the adjustment tool sections together into one
- Check that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.
Installing the front camshaft seal
- Use drift 999 5718 Drift 999 5718 Drift.
- Lubricate the surface of the seal that the camshaft rotates against
- Use the mounting screws for the variable valve timing unit
- Tighten the screws until the drift bottoms out.
Installing the thermostat housing
Install:
- the screw holding the inner timing cover to the cylinder head
- the thermostat housing and cable duct. Use a new gasket
- the screw for the thermostat housing cable duct.
Checking the tensioner pulley and idler pulley
- Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 24 Nm
- Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw. Screw in the center screw by hand.
- Ensure that the tensioner fork is centered over the cylinder block rib/bracket. Ensure that the Allen hole on the eccentric is at 10 o'clock.
Installing the variable valve timing (VVT) unit on the exhaust camshaft
- Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit
- Press the variable valve timing unit and timing gear onto the camshaft
- Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly
- Turn the variable valve timing unit counter-clockwise as far as it will go. Slacken off the center screw
- Position the upper timing cover
- Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cogs before the marking on the upper timing cover.
Note! Do not turn counter-clockwise during this procedure.
- Check that the timing gear pulley is still in the limit position in the oval holes
- Tighten the center screw in the VVT unit. See Tightening torque, B6324S Tightening Torque. Check that the variable valve timing unit does not rotate when tightening
- Install and tighten the centre plug according to Tightening torque, B6324S Tightening Torque.
Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.
Installing the variable valve timing (VVT) unit on the intake camshaft
- Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit
- Press the variable valve timing unit / timing gear onto the camshaft
- Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly
- Turn the variable valve timing unit counter-clockwise as far as it will go
- Slacken off the center screw
- Turn the timing belt pulley clockwise until the screws at the oval holes are in the end-position. Continue turning clockwise until the timing belt pulley marking is 2 cogs before the marking on the upper timing casing.
Note! Do not turn counter-clockwise during this procedure.
- Check that the timing gear pulley is still in the limit position in the oval holes
- Tighten the center screw in the VVT unit. See Tightening torque, B6324S Tightening Torque. Check that the variable valve timing unit does not rotate when tightening
- Install and tighten the center plug. See Tightening torque, B6324S Tightening Torque.
Turn the variable valve timing unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.
Finishing
Tighten the timing belt tensioner center screw. Tighten to 5 Nm.
Install the timing belt in the following order:
- crankshaft
- the idler pulley
- intake cam
- exhaust cam
- water pump
- tension pulley.
The variable valve timing units do not have a return spring and are easily dislodged when reinstalling the timing belt. Check that the markings correspond
Note! Adjust the timing belt pulleys so that the screws do not end up in an end-position in the oval holes.
Preparations for adjusting the timing belt
This adjustment is to be made with a cold engine. A suitable temperature is approximately 20 °C/68 °F.
At a higher temperature, for example, with a warm engine or a higher ambient temperature, the needle is further to the right.
The illustration shows the position of the indicator at different engine temperatures.
Adjusting the timing belt
Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position.
Turn the eccentric back so that the indicator reaches the marked position in the center of the window.
Remember to hold the center screw secure at the same time.
Hold the eccentric secure and tighten the center screw. Tighten to 25 Nm.
Check that the indicator is in the correct position.
Check:
- that the timing gear pulley is not in the limit position in the oval holes
- the timing gear pulley so that the markings line up with the upper timing cover.
Tighten the screws for the timing gear pulleys. See Tightening torque, B6324S Tightening Torque.
Removing tools
Remove:
- the camshaft adjustment tools 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
- the crankshaft stop 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
Install the plug with a new blind cover plug. Tighten to 40 Nm.
Checking the markings and belt tension
- Press the timing belt to check that the indicator on the tensioner moves easily
- Position the upper timing cover
- Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively
- Check that the indicator on the belt tensioner is within the marked position
- Remove the upper timing cover.
Installing components
Install:
- the trigger wheel.
Caution! Only fits one way, make sure you get it right
- the camshaft position (CMP) sensor housing
- the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm.
Install:
- the ignition coils according to the earlier markings
- the connector for the engine coolant temperature sensor
- the connectors for the variable valve timing solenoids
- the screws for the 2 ground terminals between ignition coils 1 and 2 and 5 and 6.
Installing components at the intake manifold
Install:
- the starter motor
- the throttle body (TB) connector to the engine wiring
- the charge air pipe to the throttle body (TB). Tighten the clamp
- the brake vacuum hose to the intake manifold
- the pipe screws at the underside of the intake pipe for the water heated crankcase ventilation. Tighten to 26 Nm
- the dip stick pipe onto the intake manifold.
Installing the fuel rail
- the fuel rail. Use new screws. Tighten to 10 Nm. Press the quick-release connector for the fuel pressure line until it clicks
- the clamps that hold the injector wiring and the positive cable to the rear edge of the cylinder head
- the protective cover over the nozzle connectors
- the upper engine coolant hose to the cylinder head and radiator. Tighten the clamp.
Installing the intake pipe for the coolant pump
Note! Apply thread sealant 1161 056 on the screws.
Install:
- the inlet pipe for the coolant pump to the cylinder head. Use a new gasket
- the screw which secures the coolant pump inlet pipe to the cylinder block
- The turbocharger (TC). See Turbocharger (TC), replacing Turbocharger (TC), Replacing.
Installing components
Install:
- the bracket for the torque rod
- the upper screw securing the automatic transmission dip stick pipe to the engine
- the ground strips between the right frame member and the cylinder head.
- the cable duct on the inside of the right suspension turret
- the front timing cover.
- expansion tank. Connect the connector to the coolant level sensor
- the hose to the expansion tank from the radiator. Secure the clamp and remove the lock grip pliers. Connect the connector to the ABS sensor
- the servo reservoir. Ensure that the hoses are correctly positioned.
Install:
- the upper timing cover
- the cover over the ignition coils
- the plastic intake pipe over the engine. Adjust and tighten the intake pipe at the turbocharger (TC). Tighten the clamps and mounting screws on the plastic pipe
- the plastic charge air pipe over the engine. Tighten the clamps and mounting screws
- the hose between the charge air cooler (CAC) and the plastic charge air pipe over the engine. Tighten the clamps
- the crankcase ventilation hose to the PTC resistor in the plastic intake pipe over the engine. Use a new clamp
- the connector for the PTC resistor
- the protective cover over the PTC resistor
- the EVAP hose to the plastic intake pipe
- the air cleaner (ACL) assembly
- the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp
- the connector to the mass air flow (MAF) sensor. Clamp the wiring at the front of the air cleaner (ACL)
- the turbocharger (TC) control valve to the mounting on the air cleaner (ACL)
- the blue marked hose and the turbocharger (TC) control system to the intake manifold
- the red marked hose and turbocharger (TC) control system to the charge air pipe
- the yellow marked hose and turbocharger (TC) control system to the pressure regulators
- the cross stay between the suspension turrets
- the suspension turret covers. Clamp the servo hose to the right mounting on the engine stabilizer brace
- the battery negative lead. Also read Battery, disconnecting Battery Disconnecting.
Checking and topping up
Replace the oil and oil filter if necessary.
Check:
- the engine oil level
- the servo oil level
- the coolant level.
Warm up the engine until the thermostat opens.
Check:
- the engine for leaks
- the oil level in the transmission
- the coolant level.
Top up if necessary.