Engine - Removal, Replacement and Installation: Other Volvo S80 I

Crankshaft Seal Rear, Replacing

Special tools

See 9995112

See 9995651

See 9991801

See 9995678

See 9997174

See 9512050

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Scheme 108

Remove the gearbox

1. See «Gearbox, removing»(ref-461734-S17518961352012040200000) .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Scheme 109

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Scheme 110

Note. To clean the crankshaft, use cloth 9511024.

Installing The Sealing Ring

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Scheme 111

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool: 9997174 . Discard the old screws for the flywheel.

Scheme 112

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) .
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) .
3. Then angle tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Installing The Gearbox

Install the gearbox

1. For gasoline 4T65 1999- see «Transmission, installing»(ref-440317-S27549153362011121400000)
2. For gasoline AW50-42 1999- see «Transmission, installing»(ref-461714-S21053673272012040200000) .
3. For gasoline AW55-50 -2000 see «Installing the gearbox»(ref-461732-S00491095272012040200000) .
4. For gasoline AW55-50 and AW50AWD (AMB) 2001- see «Installing the gearbox»(ref-440317-S12267036382011121400000)

Checking The Engine

Test drive the car to check the function of the engine and the gearbox.

Crankshaft Seal, Front, Replacing

Replace the front crankshaft seal. See Oil pump / crankshaft seal, front, replacing .

Replacing The Carrier Plate

Special tools

See 9995112

See 9995678

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Preparatory Work

Remove the transmission according to Gearbox, removing .

Removing The Carrier Plate

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Scheme 113

Block the carrier plate using gear sector 9995112 .

Remove

1. all screws
2. the carrier plate
3. gear sector «9995112»(ref-403953-S01318438012011061000000) .

Scheme 114

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Scheme 115

Note. Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean.

Use tool 9995678 , which consists of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) , distributed as illustrated
2. the carrier plate.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

Locate gear sector 9995112 against the carrier plate.

Pull the flywheel towards the crankshaft using the three nuts on special tool 9995678 .

Install 7 new screws. Tighten crosswise. Tighten to 45 Nm .

Remove the 3 nuts and studs.

Install the remaining 3 new screws. Tighten the screws. Tighten to 45 Nm . Then angle-tighten all 10 screws crosswise to 50°.

Install the engine speed (RPM) sensor with the bracket. Tighten to 10 Nm .

Finishing

Install the transmission according to Installing the gearbox .

Special tools

9512050

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.

Note. For tightening torques, see: Tightening torque .

Installing the gearbox

Scheme 116

Before installing the transmission it is very important that the checks and cleaning have been carried out. See: Transmission, preparations before installing .

Adjust for height and angle using the mobile jack and the gearbox fixture.

Align the gearbox against the engine.

Note. Make sure that the gearbox goes straight in relation to the engine and that the guide sleeves and locating pin for the starter motor fit into the guide holes on the gearbox.

Installing and tightening the screws to the gearbox

Scheme 117

Fit the screws, 7 x M10, to the gearbox/engine.

First tighten alternately and crosswise with light contact, while checking that the gearbox and engine are in contact all the way around.

Following which, tighten the screws with light contact crosswise to the gearbox/engine. Tighten.

Remove the fixture from the gearbox.

Fitting the torque converter screws.

Scheme 118

Note. Use new screws, Torx TX50.

Align the torque converter to the carrier plate, by means of pulling round the engine with the nut to the crankshaft pulley and turning the torque converter.

Fit all screws, 6, loosely. Insert the screws as far as the screw heads sit against the carrier plate. Tighten in accordance with: Summary of tightening torques for specific components .

Note. Remove the socket wrench from the crankshaft.

Lifting the engine/gearbox

Scheme 119

Lift up the engine/gearbox. Check that the engine/gearbox is in horizontal position.

Raise the vehicle.

Installing the rear engine mounting

Scheme 120

Install

1. the rear engine mounting, 3 x M10, to the gear box. Tighten
2. the screw to the engine pad/steering gear loosely.

Installing the angle gear

Note. Only applies to vehicles with four-wheel drive AWD

Scheme 121

Note. Before installing the angle gear the splined joint between the gearbox and the angle gear must be lubricated with grease in accordance with: Splines greasing .

Check that the contact surfaces on the gearbox and the angle gear are clean.

Fit the angle gear. Tighten the screws, M10, alternately to light contact. Tighten.

Installing the lower oil pipe to the gearbox

Scheme 122

Use a new O-ring.

Install

1. the oil pipe. Tighten the lower screw, 1 x M6.
2. the upper screw (oil pipe/dipstick pipe). Tighten in accordance with: «Summary of tightening torques for specific components»(ref-440306-S14604869972011121400000) .
3. a tie strap to the cable harness/oil pipe
4. the ground cable to the engine.

Installing the left-hand drive shaft to the gearbox and the wheel spindle

Scheme 123

Note. Check that the seal is fitted on the drive shaft.

Fit the drive shaft joint sealing ring in accordance with: Seal CV joint housing, replacing .

Press the drive shaft joint in so that the lock ring engages its groove in the gearbox. Check by pulling in the joint housing.

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Fitting the subframe to the body

Scheme 124

Note. Use new screws. Lubricate the screws' threads.

Applies to certain models.

Raise the subframe so that it remains approx. 150 mm before reaching the side member.

Secure the servo line with the rubber clamp in the front on the top of the frame. Fit the screw loosely.

Note. When the subframe is raised, make sure that the spring strut ball joint pin aligns in the link arm.

Install

1. the new screws and the support bracket at the back
2. the bracket screws loosely.

Tighten the subframe screws to light contact.

Remove the mobile jack.

Installing the right-hand drive shaft to the gearbox, wheel spindle and link arm

Scheme 125

Fit the bearing cap to the drive shaft support bearing, 2 x M8.

Tighten.

Note. Make sure that the seal is fitted on the drive shaft.

Fit the drive shaft joint sealing ring in accordance with: Seal CV joint housing, replacing .

Align the drive shaft in the wheel hub. Fit a new screw loosely in the drive shaft.

Press the link arm down and align the spring strut ball joint pin in the link arm.

Position the mobile jack under the right-hand side of the subframe with light contact. Remove both subframe screws.

Install

1. new screws in the subframe

Note. Lubricate the screws' threads.

1. the screws loosely in the support plate at the rear.

Tighten the subframe screws to light contact.

Remove the mobile jack.

Tightening the subframe screws (both sides)

Scheme 126

Install the four subframe screws together with the subframe brackets and engine heater where appropriate.

Tighten to: Tightening torque . First tighten the screws on the left-hand side of the subframe followed by those on the right.

Tighten the bracket screws M10.

Tighten the screws, 4 x M10, to the subframe brackets.

Fitting the screws for engine pads and the torque rod bracket in the gearbox

Scheme 127

Install

1. the screws, M10, to the front and rear engine pads. Tighten

Note. Use new screws.

1. the torque rod bracket to the transmission. Tighten. See «Summary of tightening torques for specific components»(ref-440306-S14604869972011121400000) .

Installing the steering wheel shaft joint

Scheme 128

Align the steering wheel shaft joint on the steering gear.

Fit a new steering wheel shaft screw. Tighten in accordance with: Summary of tightening torques for specific components .

Connect the cable to the stepper motor/solenoid.

Check the position of the tie rod in the steering gear in accordance with Measuring the position of the tie rod in the steering gear .

Installing the crossmembers

Scheme 129

Install

1. the front crossmember and the brake pipe in their holders
2. the other 2 crossmembers.

Tighten all M8 screws.

Installing and tightening the front suspension components

Scheme 130

Fit the nut to the ball joint pin. Counterhold the ball joint pin while tightening so that the gaiter does not turn. Use a new nut, M12.

Tighten, see: Summary of tightening torques for specific components .

Tighten the drive shaft screw. Use a new screw. Counterhold with a screwdriver in the brake disc. Tighten in accordance with: Summary of tightening torques for specific components . Use: 9512050 .

Fit on the left-hand side

1. the link to the anti-roll bar. Counterhold the ball joint pin while tightening so that the gaiter does not turn. Use a new lock nut. Tighten in accordance with: «Summary of tightening torques for specific components»(ref-440305-S42488025292011121400000) .
2. the tie rod. Tighten in accordance with: «Summary of tightening torques for specific components»(ref-440307-S04130719572011121400000) .

Install

1. the ABS line to the bracket in the spring strut
2. the wing liner with support plate and nuts.

Installing the cable conduit

Scheme 131

Install

1. the cable duct to the subframe
2. the ground cable to the subframe
3. auxiliary heater/parking heater to the bracket in the subframe and the fuel line to the brackets (if fitted to the vehicle)
4. the front splash guard
5. the splash guard under the engine
6. the wheels. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Removing the lifting beam

Scheme 132

Lower the vehicle.

Remove the lifting beams and lifting hooks from the engine.

Installing the water hose

Scheme 133

Fit the water hose quick attachment to the heater.

Remove the hose clips.

Fitting the remaining screws to the gearbox/starter motor

Scheme 134

Install

1. the screws, 3 x M10, to the gearbox/engine. Tighten
2. the screws for the starter motor. Tighten. See: «Summary of tightening torques for specific components»(ref-440295-S42438549802011121400000)
3. the bracket to the coolant hose-cable harness
4. the bracket to the cable harness clamp and the bracket for the heated oxygen sensor (HO2S) connectors in the rear edge of the gearbox
5. the clamp to the cable harness at the rear edge of the engine
6. the bracket for the air cleaner (ACL), 2 x M10. Tighten (Applies only to B5254T4).

Installing the gear selector cables and oil line

Scheme 135

Install

1. the ground cable with bracket to the subframe
2. the oil pipe to the gearbox
3. the gear selector cables with the bracket, 2 x M8. Tighten.

Connect the cable to the lever. Connect the gearbox connector and the bracket to the air cleaner (ACL) housing bracket.

Press the cable harness bracket onto the control system cover.

Installing service clips

Scheme 136

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.

Scheme 137

Check that the clip is positioned in the groove as illustrated.

Installing engine compartment components

Scheme 138

Applies only to turbocharged engines, fit

1. the control valve to the fan cover
2. the charge air pipe over the engine
3. the air cleaner (ACL) housing assembly with the intake manifold and connections
4. the cover at the side of the air cleaner (ACL) housing (Applies only to B5254T4)
5. the ground cable to the bracket on the engine (certain variants)
6. the upper torque rod between the wheel housings. Tighten the screws, M10
7. the screw, M12, to position rod/engine mounting. Tighten.

Scheme 139

Scheme 140

Applies only to naturally aspirated engines, fit

1. the air cleaner (ACL) housing with the intake manifold and preheating hose
2. the vacuum hoses, 2, from the intake manifold to the control valves
3. the ground cable to the bracket on the engine (certain variants)
4. the upper torque rod between the wheel housings. Tighten the screws, M10
5. the screw, 1 x M12, to the torque rod/engine mounting. Tighten.

Installing the battery cable

Install the battery cable. See Battery, disconnecting .

Check

After work in the gearbox checking must be performed in accordance with: Transmission replacement, post-checking .

Special tools

See 9995112

See 9997174

See 9991801

See 9995678

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removing The Flywheel And Carrier Plate

Remove the gearbox

1. See «Gearbox, removing»(ref-461734-S17518961352012040200000) .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Removing The Seal

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Note. To clean the crankshaft, use cloth 9511024.

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Scheme 141

Thread the seal onto the bevelled part of the inner section of 9997174 with the felt side of the seal outward.

Screw the drift onto the crankshaft (2 screws) of the flywheel.

Pull in the seal with the outer part of the drift, 9997174 , using the screw in the center of the tool. The seal is in place when the outer drift bottoms against the inner drift. Remove tool 9997174 . Scrap the old flywheel screws.

Installing Flywheel And Carrier Plate

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) .
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) .
3. Then angle-tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Install the gearbox

1. For gasoline 4T65 1999- see «Transmission, installing»(ref-440317-S27549153362011121400000)
2. For gasoline AW50-42 1999- see «Transmission, installing»(ref-461714-S21053673272012040200000) .
3. For gasoline AW55-50 -2000 see «Installing the gearbox»(ref-461732-S00491095272012040200000) .
4. For gasoline AW55-50 and AW50AWD (AMB) 2001- see «Installing the gearbox»(ref-440317-S12267036382011121400000)

Test drive the car to check the function of the engine and the gearbox.

See Crankshaft seal, front, replacing

See Replacing the carrier plate

Special tools

9995112

9995651

9991801

9995678

9997174

9512050

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Remove the gearbox

1. See «Gearbox, removing»(ref-461734-S17518961352012040200000) .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Note. To clean the crankshaft, use cloth 9511024.

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool: 9997174 . Discard the old screws for the flywheel.

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of tightening torques for specific components»(ref-440294-S00175651242011121400000) .
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of tightening torques for specific components»(ref-440294-S00175651242011121400000) .
3. Then angle tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of tightening torques for specific components»(ref-440294-S00175651242011121400000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Install the gearbox

1. See «Gearbox, removing»(ref-461734-S17518961352012040200000) .

Test drive the car to check the function of the engine and the transmission.

Special tools

9995112

9995678

Remove the transmission according to Transaxle, removing .

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Block the carrier plate using gear sector 9995112 .

Remove

1. all screws
2. the carrier plate
3. gear sector «9995112»(ref-403953-S01318438012011061000000) .

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Installing The Carrier Plate

Note. Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean.

Use tool 9995678 , which consists of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) , distributed as illustrated
2. the carrier plate.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

Locate gear sector 9995112 against the carrier plate.

Pull the flywheel towards the crankshaft using the three nuts on special tool 9995678 .

Install 7 new screws. Tighten crosswise. Tighten to 45 Nm .

Remove the 3 nuts and studs.

Install the remaining 3 new screws. Tighten the screws. Tighten to 45 Nm . Then angle-tighten all 10 screws crosswise to 50°.

Install the engine speed (RPM) sensor with the bracket. Tighten to 10 Nm .

Install the transmission according to Transmission, installing .

See Crankshaft seal rear, replacing

Replacing Front Crankshaft Seal

Replace front crankshaft seal according to Oil pump / crankshaft seal, front, replacing .

See Replacing the carrier plate

See Crankshaft seal rear, replacing

Oil Pump / Crankshaft Seal, Front, Replacing

Special tools

See 9995304

See 9995919

See 9995455

See 9995433

Preparation

Remove the timing belt. See Removing the timing belt .

Check the tensioner and idler pulleys. See Checking the tensioner pulley and idler pulley .

Scheme 142

Carefully pull away the timing gear pulley. Use puller 9995304 .

Scheme 143

Remove the old seal. Use extractor 9995919 .

Clean sealing surfaces.

Lubricate and install the new seal. Use drift 9995455 .

Press in drift and seal with crankshaft center nut.

Note. Ensure that the crankshaft does not rotate when pressing in the crankshaft seal.

Scheme 144

Remove the four oil pump screws.

Carefully pry upward diagonally between the stop lugs and the cylinder block.

Lift out the oil pump.

Scheme 145

Install a new gasket .

Carefully insert the oil pump over the end of the crankshaft.

Note. The sealing ring in the oil pump is very easy to damage if not installed correctly.

Install four new screws as a guide.

Pull in the oil pump with drift 9995455 and the crankshaft center nut.

Tighten the oil pump screws. Tighten to 10 Nm .

Install the timing gear pulley. Carefully tap alternately around the timing gear pulley until reaching its end position.

Note. The timing gear pulley can only be in one position on the crankshaft end splines.

Scheme 146

Install a new timing belt . See Installing the timing belt .

Install the pulley for the auxiliaries belt. Locate the steering gear on the locating pin in the timing gear pulley.

Install the auxiliaries belt.

Install counterhold 9995433 .

Tighten the crankshaft center nut. Tighten to 300 Nm .

Install the vibration damper using new screws . Tighten to 35 Nm . Angle-tighten 50° . Use the crankshaft center nut as a counterhold.

Final Check

Check the engine oil level. Top up if necessary.

Test drive the engine.

See Replacing the carrier plate

Depressurizing The Fuel System

Lower the car.

Depressurize the fuel system acc. to: Fuel system pressure release .

Scheme 147

Remove

1. the engine stabilizer brace between the suspension turrets
2. the ground strips between the engine and the firewall
3. the heat deflector plate above the turbocharger (TC)
4. the plastic charge air pipe above the engine. Seal the openings
5. the cover over the nozzle pipes
6. the cover over the ignition coils
7. the upper engine coolant hose for the engine and radiator
8. the screw holding the dip stick pipe to the intake manifold
9. the brake vacuum hose from the intake manifold.

Undo the clamp holding the plastic charge air pipe to the electronic throttle module.

Scheme 148

Remove

1. the connector from the mass air flow (MAF) sensor
2. the intake hose from the mass air flow (MAF) sensor. Seal the opening.

Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket.

Remove

1. the clamp for the positive lead at the rear of the cylinder head
2. the torque bracket
3. the pipe screw for the water-heated crankcase ventilation.

Scheme 149

1. Remove the clamp for the injector wiring at the rear of the cylinder head
2. Detach the wiring from the injectors
3. Remove the fuel rail mounting screws
4. Spray universal oil or similar around the injector connectors on the intake manifold
5. Gently work the fuel rail and injectors loose
6. Separate the quick-release connector for the fuel line. See «Fuel line, lock»(ref-461787-S19854223012012040200000) .
7. Carefully put the fuel rail to one side.

Scheme 150

1. Mark up the ignition coils so that their original positions can be established
2. Remove the mounting screws for the ignition coils and the screws at the two ground terminals
3. Disconnect the connector for the variable valve timing solenoid
4. Lift up and place the ignition coils and wiring to one side.

Remove

1. the crankcase ventilation hose from the top of the camshaft cover
2. the camshaft position sensor (CMP) housing and trigger wheel.

Scheme 151

Remove

1. The EVAP hose from the intake manifold
2. the by-pass valve vacuum hose. Disconnect the connector for the electronic throttle module (ETM)
3. the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws. Lift up the intake manifold. Remove the pipe screw for the water heated crankcase ventilation underneath the intake manifold
4. the pipe screw for the crankcase ventilation from the underside of the intake manifold.

Lift up and remove the intake manifold.

Note. Make sure that the fuel pressure pipe is not damaged.

Scheme 152

Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.

Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Note. Make sure that oil does not leak from the breather hole in the filler cap.

Remove the auxiliaries belt.

Remove

1. front timing cover
2. the hose for the water-heated crankcase ventilation from the thermostat housing.

Separate the connector for the engine coolant temperature (ECT) sensor.

Scheme 153

Remove the nuts from the cover on the fender liner.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.

Remove the upper timing cover.

Removing The Timing Belt

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.

Remove

1. the timing belt from the timing gear pulley
2. the screw that holds the inner timing cover to the cylinder head.

Install tool 9995452 at the rear of the camshafts.

Removing The Timing Gear Pulley

Remove the cable duct from its mountings on the right-hand suspension turret.

Note. Do not damage the paintwork.

Hold the cable duct out of the way and remove

1. the plug at the front of the variable valve timing unit (TX55). NOTE: Use paper or similar to absorb oil that drains.
2. the center screw in the variable valve timing unit (TX55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Remove tool 9995452 .

Scheme 154

Remove

1. the heat deflector plate above the manifold
2. the upper engine coolant pipe. Place it to one side
3. the oil pressure pipe for the turbocharger (TC)
4. the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side
5. the nuts and washers holding the manifold to the cylinder head.

Lift off the turbocharger and manifold. Carefully put them on top of the transmission.

Scheme 155

Remove

1. the screw that holds the coolant pump intake pipe to the engine block a few turns. Leave the screw in place
2. the two screws for the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

Scheme 156

1. Remove the spark plugs from cylinders 1 and 5
2. Install 2 tools «9995454»(ref-403953-S30108818292011061000000) . Leave a 2-3 mm gap to the camshaft cover. NOTE: Make sure that the screw in the spark plug thread is fully tightened. VVT-solenoid (variable valve timing).
3. The variable valve timing solenoids.
4. Remove all the screws securing the camshaft cover to the cylinder head.

Scheme 157

1. Use pliers «9995670»(ref-403953-S00526374942011061000000) to lift the cover from the cylinder head.
2. Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backwards
3. Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Scheme 158

Carefully press out the front and rear camshaft seals.

Scheme 159

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000)
2. the camshaft cover
3. the camshafts
4. the screws holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center.

Get some help and lift of the cylinder head. Place the cylinder head on two wooden blocks.

Note. Work carefully to avoid damaging the contact faces.

When Replacing Or Working On The Cylinder Head

Lift out the valve lifters. Use a magnet or suction cup.

Remove the thermostat housing and transfer it to the new cylinder head.

Note. Work carefully to avoid damaging the contact faces.

Note. For tightening torques, see: Tightening torque .

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Scheme 160

Clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the coolant bypass channel
3. the thermostat housing
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Scheme 161

1. Position the crankshaft
2. Remove the starter motor mounting screws. Pull out the starter motor and place it to one side
3. Remove the blind cover plug
4. Turn the crankshaft slightly clockwise .
5. Install crankshaft stop «9995451»(ref-403953-S26663901482011061000000) . Ensure that it bottoms out against the cylinder block.
6. Turn the crankshaft counter-clockwise until it stops against the crankshaft stop
7. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Scheme 162

1. Ensure that all studs at the exhaust ports are tightened
2. Lubricate the studs with paste 116 1408.
3. Install a new cylinder head gasket
4. Install the cylinder head
5. Lubricate and install all the screws (use new screws).
6. Tighten the screws as illustrated. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) . Use protractor «9512050»(ref-403953-S36645634772011061000000) .

Scheme 163

1. Lubricate the valve lifter wells. NOTE: If the cylinder head has been replaced, the valve clearance must be adjusted. See «Valve clearance»(ref-440282-S27393712532011121400000) .
2. Install all valve lifters
3. Lubricate the camshaft bearing positions
4. Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line
5. Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line.

Scheme 164

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 1161 059 to the camshaft cover.

Use roller 9512767 . The surface must be covered without any excess .

Note. Make sure that no liquid gasket ends up in the oil channels.

Installing The Camshaft Cover

1. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters
2. Install the camshaft cover
3. Install press tool «9995454»(ref-403953-S30108818292011061000000) (2x).
4. Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools
5. Install all the screws. Tighten the screws from the middle and outwards
6. Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket.
2. the spark plugs. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000)
3. the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.

Connect the connector for the engine coolant temperature (ECT) sensor.

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, 116 056 to the screw threads.

Tighten the screw for securing the coolant pump inlet pipe to the cylinder block.

Scheme 165

Install

1. new gaskets. Lift and install the manifold and turbocharger (TC)
2. the nuts and washers holding the manifold to the cylinder head
3. the upper and lower turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose
4. the pipe screws for the coolant pipes. Use new seal washers. Tighten
5. the oil pressure pipe
6. the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. Do not tighten.

Lubricate the studs on the turbocharger (TC). Use paste 116 1408 .

Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten. Install the heat deflector plate over the manifold.

Scheme 166

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. For cleaning, work around the shaft journal - not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new seal ring is installed.

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Scheme 167

1. Use drift «9995718»(ref-403953-S24775656662011061000000) .
2. Lubricate the surface of the seal that the camshaft rotates against.
3. Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out
4. Remove the drift
5. Install the screw holding the inner timing cover to the cylinder head.

Checking And Adjusting The Variable Valve Timing Unit

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Scheme 168

Install

1. front timing cover
2. the cable duct to the mountings on the right suspension turret
3. the auxiliaries belt
4. the expansion tank
5. the servo oil reservoir
6. the bleed hose to the expansion tank. Tighten the clamp.

Check that the hoses are installed correctly.

Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.

Scheme 169

Install

1. the starter motor
2. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm
3. the camshaft position sensor (CMP) housing and trigger wheel
4. the lower engine stabilizer brace bracket in the cylinder head
5. the upper engine stabilizer brace.

Scheme 170

Install

1. the bracket and lifting eyelet for the engine stabilizer brace bracket
2. the ignition coils and ground terminals according to earlier markings. Connect the connector for the variable valve timing solenoid
3. the clamp for the positive lead at the lifting eyelet bracket
4. the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp.

Connect the connector to the mass air flow (MAF) sensor. Use a clamp on the wiring at the front of the air cleaner (ACL).

Scheme 171

Clean the intake manifold gasket face to the cylinder head.

Install a new gasket on the cylinder head. Secure with the two screws in the lower row.

Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.

Note. Work carefully to avoid damaging the fuel pressure pipe.

Route the crankcase ventilation hose through the cavity in the intake manifold.

Install

1. the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm
2. the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm
3. the hose to the canister purge (CP) valve
4. the control hose for the turbocharger (TC) by-pass valve
5. the brake vacuum hose
6. the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
7. the cover over the ignition coils
8. the upper timing cover
9. the upper engine coolant hose for the engine and radiator. Tighten the clamp
10. the screw holding the dip stick pipe to the intake manifold. Connect the connector to the electronic throttle module (ETM)
11. the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.

Scheme 172

Install

1. the fuel rail. Use new screws. Press the quick-release connector for the fuel pressure line until it clicks. See «Fuel line, lock»(ref-461787-S19854223012012040200000)
2. the clamp for the injector wiring at the rear of the cylinder head
3. the protective cover over the injector connectors
4. the charge air pipe over the engine. Tighten the pipe using the three screws on the engine. Tighten the clamps.

Installing Components

Raise the car. Install

1. the pipe screw that holds the turbocharger (TC) oil pressure pipe to the engine. Use new seal washers. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000)
2. the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten. See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000)
3. the clamp between the oil pressure pipe and the oil return line. Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC). See «Summary of specific components and tightening torques»(ref-440294-S04852036502011121400000) .
4. the lower screw for the heat deflector plate over the turbocharger (TC)
5. the splash guard under the engine
6. the plastic nuts for the hatch in the right fender liner
7. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Lower the car.

Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. See Summary of specific components and tightening torques .

Install

1. the ground strips between the cylinder head and the firewall
2. the engine stabilizer brace between the suspension turrets Clamp the servo hose at the right-hand engine stabilizer brace mounting
3. the negative battery lead. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Check

Replace the oil and oil filter if necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Cylinder Head/Gasket, Replacing

Special tools

See 9512666

See 9512767

See 9995450

See 9995452

See 9995454

See 9995670

See 9995718

See 9995719

See 9995750

See 9995972

Removing The Cylinder Head Gasket

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Scheme 173

The terms turbo 1 and turbo 2 are used to simplify the text below. Turbo 1 stands for the turbocharger for cylinders 1, 2 and 3. Turbo 2 stands for the turbocharger for cylinders 4, 5 and 6.

Remove

1. the negative battery lead. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .
2. the radiator breather tube by the expansion tank. Install lock grip pliers.
3. the right-hand drive shaft and viscous coupling. See «Drive shaft right, replacing»(ref-440352-S00478927422011121400000) .
4. the bearing seat for the drive shaft from the cylinder block.
5. the pipe screw for the turbocharger oil pressure pipe by the cylinder block.

Scheme 174

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Scheme 175

Remove

1. the 8 nuts at the front exhaust system connection to the turbocharger exhaust bends.
2. the first mounting bracket for the exhaust system downstream of the catalytic converter from the body.
3. the front SIPS member from the body.
4. the brake pipe from the holders on the SIPS member.

Press the exhaust system back so that there is 60-70 mm of play at the branching downstream after the turbocharger.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Remove the gaskets.

Seal the openings at the exhaust system.

Scheme 176

Remove

1. the cross stay between the suspension turrets.
2. plastic pipes, intake/charge air over the engine.
3. upper coolant hose engine/radiator.
4. solenoid valve (turbo control) from the air cleaner.
5. the air cleaner inlet pipe from the connection on the front cover plate.
6. the air cleaner assembly.

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

First remove the upper timing cover and then the front timing cover.

Remove the cover over the ignition coils.

Releasing The Coolant Pump Inlet Pipe

Remove

1. the screw that holds the coolant pump inlet pipe onto the cylinder block.
2. 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 wing liner.

Position the upper timing cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts align.

Remove the upper timing cover.

Scheme 177

Remove

1. the connector for the variable valve timing solenoid.
2. the connector for the coolant temperature sensor.
3. the screws for the ignition coils and the two ground terminals.

Lift up and place the ignition coils and wiring to one side.

Note. Mark up the ignition coils before removal.

Scheme 178

Assemble tool 9995750 . Install the tool between the lever pulley and the lifting lug at the servo pump.

Slacken off the screw in the tool so that there is clearance of approximately 10 mm between the screw head and the tool.

Allow the tool spring to compress the tensioner / damping unit.

Scheme 179

Install tool 9995452 at the rear of the camshafts.

Check that the tensioner / damper unit has been compressed.

Remove the timing belt.

Remove

1. the variable valve timing unit center plug.
2. variable valve timing unit center screw. Pull / pry off the variable valve timing unit and timing belt pulley.
3. screws holding the timing belt (without the variable valve timing unit) to the camshaft.
4. the timing belt pulley.
5. tool 999 5452.

Scheme 180

Remove

1. the screw for the thermostat housing cable duct.
2. the screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct.
3. the screw holding the inner timing cover to the cylinder head.

Scheme 181

Remove

1. spark plugs for cylinders 2 and 5. Install tool 999 5454 (x2). Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened.
2. Variable valve timing solenoid.
3. the screws holding the camshaft cover to the cylinder head.

Scheme 182

Use pliers 9995670 to lift the cover from the cylinder head.

Install 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.

Scheme 183

Remove

1. tools 999 5454.
2. the camshaft cover.
3. the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Note. Work very carefully to avoid damaging the contact faces.

When Replacing/Machining The Cylinder Head

Lift out the valve lifters. Use a magnet or suction cup.

Note. Keep the tappets in an oil-filled container to avoid self-drainage.

Remove

1. the intake manifold and gasket.
2. the coolant outlet pipe.

Scheme 184

Clean the gasket faces for

1. the manifold. Check that the studs are tightened.
2. the coolant bypass channel
3. the coolant outlet pipe.
4. intake manifold.
5. engine block.
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent 1161 440 . Use a fume hood or extractor when using gasket solvent

Installing The Cylinder Head Gasket

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Installing Valve Lifters And Camshafts

Lubricate the valve guide wells.

Install all valve lifters

Lubricate the camshaft bearing seats.

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.

Scheme 185

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 9512767 . The surface must be completely covered without any excess.

Note. Make sure that no liquid gasket gets into the oil channels.

Installing The Camshaft Covers

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with the press tools.

Install all the screws and tighten.

Install the variable valve timing solenoid with a new gasket.

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Scheme 186

Use drift 9995450 .

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 turning around the tool's sleeve.

Securing The Camshafts

Use camshaft tool 9995452 .

Separate the camshaft adjustment tool into two units.

Note. The camshafts must not be turned more than indicated 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 counterclockwise 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.

Scheme 187

Use drift 9995718 for camshaft with variable valve timing unit and drift 9995719 for camshaft without variable valve timing unit.

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Installing Thermostat Housing

Install

1. the screw holding the inner timing cover to the cylinder head.
2. the thermostat housing and cable duct. Use a new gasket
3. the screw for the thermostat housing cable duct.

Checking The Variable Valve Timing (VVT) Unit

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Scheme 188

Install

1. the trigger wheel.
2. the camshaft position sensor housing, lower screw only.
3. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm .
4. the cover at the rear edge of the intake camshaft.

Install

1. ignition coils using previous markings.
2. the connector for the coolant temperature sensor.
3. the connector for the variable valve timing solenoid.
4. the screws for the 2 ground terminals between ignition coils 1 and 2 and 5 and 6.

Scheme 189

Install below the intake manifold

1. the starter motor.
2. the throttle body (TB) connector to the engine wiring.
3. the charge air pipe to the throttle body. Tighten the clamp.
4. the control hose to the charge air bypass valve.
5. the brake vacuum hose to the intake manifold.
6. the bracket and screw to the lower row of screws at the mounting for the intake manifold on the cylinder head.
7. the pipe screws at the underside of the intake pipe for the water heated crankcase ventilation. Tighten to 26 Nm .
8. the dipstick tube to the intake manifold.

Installing The Fuel Rail

Install

1. the fuel rail. Use new screws. Tighten to 10 Nm . Press the quick-release connector for the fuel pressure line until there is an audible click.
2. the clamps holding the injector wiring and the positive cable to the rear edge of the cylinder head.
3. the protective cover over the nozzle connectors.
4. the upper coolant hose to the cylinder head/radiator. Tighten the clamp.

Installing The Coolant Pump Intake Pipe

Note. Apply thread sealant 1161 056 on to the screws.

Install

1. the coolant pump intake pipe to the cylinder head. Use a new gasket.
2. the screw for mounting the coolant pump intake pipe to the cylinder block.

Installing The Manifold And Turbo 2

Install new gaskets.

Lubricate the studs at the exhaust ports and at the flange on the turbocharger exhaust bend with paste 116 1408.

Lower and install the manifold/turbocharger.

Install

1. washers and new nuts that hold the manifold to the cylinder head.
2. the pipe screw holding the oil pressure pipe to the turbocharger. Use new sealing washers. Do not tighten.

Installing The Manifold And Turbo 1

Install new gaskets.

Lubricate the studs at the exhaust ports and at the flange on the turbocharger exhaust bend with paste 116 1408.

Lower and turn the manifold/turbocharger so that the oil pressure pipe is correctly positioned.

Install

1. washers and new nuts that hold the manifold to the cylinder head.
2. the pipe for pressure regulator control.
3. the upper screw of the camshaft position sensor housing.
4. the upper coolant pipe and hose to turbo 2. Use new sealing washers. Tighten to 26 Nm .
5. the upper coolant pipe and hose to turbo1. Use new sealing washers. Tighten to 26 Nm .

Installing Components At Turbo 1

Raise the car and install

1. the oil return pipe using a new gasket and sealing ring. NOTE: First remove the seal from the hole. Thoroughly check that the pipe and sealing ring are correctly positioned.
2. the hose to the pressure regulator.
3. the oil pressure pipe.
4. the pipe screw to the oil pressure pipe connection to the engine block. Use new sealing washers. Do not tighten.
5. the lower coolant pipe. Use new sealing washers. Tighter to 26 Nm .

Installing Components At Turbo 2

Lower the car.

Tighten the pipe screw of the oil pressure pipe to 18 Nm .

Install

1. the charge air pipe. Position and tighten the clamp.
2. the intake manifold. Align and tighten the clamp. NOTE: Remove the previously installed seals.
3. the torque rod bracket.
4. the upper screw securing the automatic transmission dipstick tube to the engine. Tighten the lower screw.
5. the heat deflector plate above the turbocharger.
6. the ground cable between the firewall and the torque rod bracket.
7. the clamp between the coolant pump intake pipe and the turbocharger oil pressure pipe.

Install

1. the pipe screw of the oil pressure pipe; use new sealing washers. Tighten to 18 Nm .
2. the heat deflector plate above the turbocharger.
3. the charge air pipe. Position and tighten the clamp.
4. the intake pipe. Install but do not tighten the clamp . NOTE: Remove the previously installed seals.
5. the ground strips between the right frame member and the cylinder head.

Scheme 190

Install

1. the cable duct on the inside of the right suspension turret.
2. the front timing cover.
3. the expansion tank. Connect the connector to the coolant level sensor.
4. 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.

1. servo reservoir. Ensure that the hoses are correctly positioned.

Install

1. the upper timing cover.
2. the cover over the ignition coils.
3. the plastic intake pipe over the engine. Adjust and tighten the intake pipe at the turbocharger. Tighten the clamps and mounting screws on the plastic pipe.
4. the plastic charge air pipe over the engine. Tighten the clamps and mounting screws.
5. the hose between the charge air cooler and the plastic charge air pipe over the engine. Tighten the clamps.
6. the crankcase ventilation hose to the PTC resistor in the plastic intake pipe over the engine. Use a new clamp.
7. the connector for the PTC resistor.
8. the protective cover over the PTC resistor.
9. the EVAP valve hose to the plastic intake pipe.
10. the bypass valve outlet hose to the plastic intake pipe. Tighten the clamp.
11. the air cleaner assembly. Press the air cleaner intake pipe into the front plate port.
12. the plastic intake pipe to the mass air flow sensor. Tighten the clamp.
13. the connector to the mass air flow sensor. Clamp the wiring at the front edge of the air cleaner.
14. the turbocharger control valve to the mounting on the air cleaner
15. the blue-marked hose/turbocharger control system to the intake manifold.
16. the red-marked hose/turbocharger control system to the charge air pipe.
17. the yellow-marked hose/turbocharger control system to the pressure regulators.
18. the cross stay between the suspension turrets
19. the suspension turret covers.

Clamp the servo hose to the right mounting on the cross stay.

Scheme 191

Raise the car.

Remove the seals at the exhaust system flanges.

Install new gaskets.

Lift and press the exhaust system against the connection at the turbocharger exhaust bends.

Note. Use a mobile jack with universal plate 9995972 as a support.

Install the screws holding the front SIPS member and rear mounting on the body. Do not tighten.

Remove the mobile jack.

Install new nuts at the exhaust gas system connection to the turbocharger.

Tighten the nuts at the exhaust system branching and the screws at the front and rear SIPS member.

Tighten the pipe screw of the oil pressure pipes to 38 Nm .

Install the drive shaft bearing seat.

Install

1. the right-hand drive shaft and viscous coupling. See «Drive shaft right, replacing»(ref-440352-S00478927422011121400000) .
2. the wheels. See «Installing wheels»(ref-440302-S30067264572011121400000) .
3. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Checking And Filling Media

Change the oil and replace the oil filter as necessary.

Check

1. the engine oil level.
2. the servo oil level.
3. the coolant level.

Warm up the engine until the thermostat opens.

Check

1. the engine for leaks.
2. the fluid level in the transmission.
3. the coolant level.

Top up as necessary.

Note. As 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.

The terms turbo 1 and turbo 2 are used to simplify the text below. Turbo 1 stands for the turbocharger for cylinders 1, 2 and 3. Turbo 2 stands for the turbocharger for cylinders 4, 5 and 6.

Remove

1. the negative battery cable. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .
2. the radiator breather tube by the expansion tank. Install lock grip pliers.
3. the right drive shaft. See: «Drive shaft right, replacing»(ref-440352-S00478927422011121400000) .
4. the bearing seat for the drive shaft from the cylinder block.
5. the pipe screw for the turbocharger oil pressure pipe by the cylinder block.

Separating The Exhaust System

Remove

1. the 8 nuts at the front exhaust system connection to the turbocharger exhaust bends.
2. the first mounting bracket for the exhaust system downstream of the catalytic converter from the body.
3. the front SIPS member from the body.
4. the brake pipe from the holders on the SIPS member.

Press the exhaust system back so that there is 60-70 mm of play at the branching downstream after the turbocharger.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Remove the gaskets.

Seal the openings at the exhaust system.

Removing Components

Remove

1. the cross stay between the suspension turrets.
2. plastic pipes, intake/charge air over the engine.
3. upper coolant hose engine/radiator.
4. solenoid valve (turbo control) from the air cleaner.
5. the air cleaner inlet pipe from the connection on the front cover plate.
6. the air cleaner assembly.

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

First remove the upper timing cover and then the front timing cover.

Remove the cover over the ignition coils.

Removing The Fuel Rail

Remove

1. the brake vacuum hose from the intake manifold.
2. the charge air pipe from the throttle body (electronic throttle module).
3. the dipstick tube from the intake manifold.
4. the pipe screw for the crankcase ventilation connection at the intake manifold.
5. the vacuum hose from the charge air bypass valve
6. the rear screw in the lower row from the connection between the intake manifold and the cylinder head; remove the bracket.
7. the protective cover over the nozzle connectors.
8. 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.

Separate the fuel line quick-release connector under the intake manifold. Use tool 9512666 .

Carefully put the fuel rail to one side.

Remove the EVAP valve hose from the intake manifold

Remove

1. the camshaft position (CMP) sensor housing and the trigger wheel.
2. the pipe screw for the water-heated crankcase ventilation.
3. the clamps for ignition coil wiring and the positive cable.
4. the cover at the rear of the intake camshaft.

Removing Components From Turbo 1

Remove from turbo 1

1. the ground strips between the engine and the firewall.
2. intake and charge air pipes, plug the openings.
3. the heat deflector plate.
4. the pipe screw for the oil pressure pipe.
5. the oil pressure pipe.
6. the pipe screws for the coolant pipes. NOTE: Place a container underneath for the coolant.
7. the upper coolant pipe with hose.

Removing Components From Turbo 2

Remove from turbo 2

1. the heat deflector plate.
2. the ground strips between the engine and the firewall.
3. the upper screw of the automatic transmission dipstick tube. Loosen the lower.
4. the torque arm bracket.
5. intake and charge air pipes, plug the openings.
6. the hose from the pressure regulator.
7. the clamp between the coolant pump inlet pipe and the turbocharger oil pressure pipe.

Raise the car and remove

1. the oil return line of turbo 1. Plug the opening in the engine block.
2. the hose from the pressure regulator.

Lower the car and remove

1. the pipe screws of the coolant pipes at turbo 2. Put the lower pipe to one side.
2. the upper coolant pipe and hose to turbo 2.
3. the air control pipe of the pressure regulator.
4. the nuts and washers of the manifold mounting at cylinders 1, 2 and 3. Lift away the manifold/turbocharger.

Remove from turbo 2

1. the screws of the oil return line. Turn the pipe to the side.
2. the pipe screw of the oil pressure pipe.
3. the nuts and washers at the manifold mounting to the cylinder head, cylinders 4, 5 and 6.

Lift off and carefully turn the turbocharger/manifold so the oil pressure pipe is released.

Note. Exercise extreme care so that the oil pressure pipe is not deformed.

Lift up and remove the turbocharger/manifold.

Remove

1. the screw that holds the coolant pump inlet pipe onto the cylinder block.
2. 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.

Remove the nuts from the cover on the wing liner.

Position the upper timing cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts align.

Remove the upper timing cover.

Remove

1. the connector for the variable valve timing solenoid.
2. the connector for the coolant temperature sensor.
3. the screws for the ignition coils and the two ground terminals.

Lift up and place the ignition coils and wiring to one side.

Note. Mark up the ignition coils before removal.

Scheme 192

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw in a fixed position. Turn the tensioner eccentric counterclockwise to 10 o'clock. Use a 6 mm Allen key.

Remove the timing belt.

Install tool 9995452 at the rear of the camshafts.

Remove

1. the variable valve timing unit center plug.
2. variable valve timing unit center screw. Pull / pry off the variable valve timing unit and timing belt pulley.
3. screws holding the timing belt (without the variable valve timing unit) to the camshaft.
4. the timing belt pulley.
5. tool 999 5452.

Removing The Thermostat Housing

Remove

1. the screw for the thermostat housing cable duct.
2. the screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct.
3. the screw holding the inner timing cover to the cylinder head.

Removing The Camshaft Cover/Cylinder Head

Remove

1. spark plugs for cylinders 2 and 5. Install tool 999 5454 (x2). Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened.
2. Variable valve timing solenoid.
3. the screws holding the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head.

Install 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

1. tools 999 5454.
2. the camshaft cover.
3. the camshafts

Lift out the valve lifters. Use a suction cup.

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Note. Work carefully to avoid damaging the contact faces.

Remove

1. the intake manifold and gasket.
2. the coolant outlet pipe.

Cleaning the gasket faces

Clean the gasket faces for

1. the manifold. Check that the studs are tightened.
2. the coolant bypass channel
3. the coolant outlet pipe.
4. intake manifold.
5. engine block.
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent 1161 440 . Use a fume hood or extractor when using gasket solvent

Note. As 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.

Aligning The Crankshaft

Remove

1. the mounting screws for the starter motor. Pull out the starter motor and place to one side.
2. the blind cover plug.

Turn the crankshaft clockwise slightly.

Install the crankshaft stop 9995451 . Ensure 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 belt pulley aligns 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.

Tighten the screws in the following order.

1. 20 Nm .

2. 60 Nm .

3. Angle tighten 130° . Use a bevel protractor 9512050 .

When installing a new cylinder head, the valve clearance must be set. See Valve clearance, setting / adjusting .

Lubricate the valve guide wells.

Install all valve lifters

Lubricate the camshaft bearing seats.

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

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 9512767 . The surface must be completely covered without any excess.

Note. Make sure that no liquid gasket gets into the oil channels.

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with the press tools.

Install all the screws and tighten.

Install the variable valve timing solenoid with a new gasket.

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Installing The Rear Camshaft Seal

Use drift 9995450 .

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.

Use camshaft tool 9995452 .

Separate the camshaft adjustment tool into two units.

Note. The camshafts must not be turned more than indicated in the text below, as this can damage valves

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 counterclockwise 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 9995718 for camshaft with variable valve timing unit and drift 9995719 for camshaft without variable valve timing unit.

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Installing The Thermostat Housing

Install

1. the screw holding the inner timing cover to the cylinder head.
2. the thermostat housing and cable duct. Use a new gasket
3. the screw for the thermostat housing cable duct.

Check the variable valve timing unit. See: Variable valve timing unit, checking and adjusting .

Install

1. the trigger wheel.
2. the camshaft position sensor housing, lower screw only.
3. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm .
4. the cover at the rear edge of the intake camshaft.

Install

1. ignition coils using previous markings.
2. the connector for the coolant temperature sensor.
3. the connector for the variable valve timing solenoid.
4. the screws for the 2 ground terminals between ignition coils 1 and 2 and 5 and 6.

Install below the intake manifold

1. the starter motor.
2. the throttle body connector to the engine wiring.
3. the charge air pipe to the throttle body. Tighten the clamp.
4. the control hose to the charge air bypass valve.
5. the brake vacuum hose to the intake manifold.
6. the bracket and screw to the lower row of screws at the mounting for the intake manifold on the cylinder head.
7. the pipe screws at the underside of the intake pipe for the water heated crankcase ventilation. Tighten to 26 Nm .
8. the dipstick tube to the intake manifold.

Install

1. the fuel rail. Use new screws. Tighten to 10 Nm . Press the quick-release connector for the fuel pressure line until there is an audible click.
2. the clamps holding the injector wiring and the positive cable to the rear edge of the cylinder head.
3. the protective cover over the nozzle connectors.
4. the upper coolant hose to the cylinder head/radiator. Tighten the clamp.

Note. Apply thread sealant 1161 056 on the screws.

Install

1. the coolant pump intake pipe to the cylinder head. Use a new gasket.
2. the screw for mounting the coolant pump intake pipe to the cylinder block.

Installing The Manifold/Turbo 2

Install new gaskets.

Lubricate the studs at the exhaust ports and at the flange on the turbocharger exhaust bend with paste 116 1408.

Lower and install the manifold/turbocharger.

Install

1. washers and new nuts that hold the manifold to the cylinder head.
2. the pipe screw holding the oil pressure pipe to the turbocharger. Use new sealing washers. Do not tighten.

Installing The Manifold/Turbo 1

Install new gaskets.

Lubricate the studs at the exhaust ports and at the flange on the turbocharger exhaust bend with paste 116 1408.

Lower and turn the manifold/turbocharger so that the oil pressure pipe is correctly positioned.

Install

1. washers and new nuts that hold the manifold to the cylinder head.
2. the pipe for pressure regulator control.
3. the upper screw of the camshaft position sensor housing.
4. the upper coolant pipe and hose to turbo 2. Use new sealing washers. Tighten to 26 Nm .
5. the upper coolant pipe and hose to turbo1. Use new sealing washers. Tighten to 26 Nm .

Installing Components To Turbo 1

Raise the car and install

1. the oil return pipe using a new gasket and sealing ring. NOTE: First remove the seal from the hole. Thoroughly check that the pipe and sealing ring are correctly positioned.
2. the hose to the pressure regulator.
3. the oil pressure pipe.
4. the pipe screw to the oil pressure pipe connection to the engine block. Use new sealing washers. Do not tighten.
5. the lower coolant pipe. Use new sealing washers. Tighter to 26 Nm .

Installing Components To Turbo 2

Lower the car.

Tighten the pipe screw of the oil pressure pipe to 18 Nm .

Install

1. the charge air pipe. Position and tighten the clamp.
2. the intake pipe. Position and tighten the clamp. NOTE: Remove the previously installed seals.
3. the torque rod bracket.
4. the upper screw securing the automatic transmission dipstick tube to the engine. Tighten the lower screw.
5. the heat deflector plate above the turbocharger.
6. the ground cable between the firewall and the torque rod bracket.
7. the clamp between the coolant pump intake pipe and the turbocharger oil pressure pipe.

Install

1. the pipe screw of the oil pressure pipe; use new sealing washers. Tighten to 18 Nm .
2. the heat deflector plate above the turbocharger.
3. the charge air pipe. Position and tighten the clamp.
4. the intake pipe. Install but do not tighten the clamp . NOTE: Remove the previously installed seals.
5. the ground strips between the right frame member and the cylinder head.

Install

1. the cable duct on the inside of the right suspension turret.
2. the front timing cover.
3. the expansion tank. Connect the connector to the coolant level sensor.
4. 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.

1. servo reservoir. Ensure that the hoses are correctly positioned.

Install

1. the upper timing cover.
2. the cover over the ignition coils.
3. the plastic intake pipe over the engine. Adjust and tighten the intake pipe at the turbocharger. Tighten the clamps and mounting screws on the plastic pipe.
4. the plastic charge air pipe over the engine. Tighten the clamps and mounting screws.
5. the hose between the charge air cooler and the plastic charge air pipe over the engine. Tighten the clamps.
6. the crankcase ventilation hose to the PTC resistor in the plastic intake pipe over the engine. Use a new clamp.
7. the connector for the PTC resistor.
8. the protective cover over the PTC resistor.
9. the EVAP valve hose to the plastic intake pipe.
10. the bypass valve outlet hose to the plastic intake pipe. Tighten the clamp.
11. the air cleaner assembly. Press the air cleaner intake pipe into the front plate port.
12. the plastic intake pipe to the mass air flow sensor. Tighten the clamp.
13. the connector to the mass air flow sensor. Clamp the wiring at the front edge of the air cleaner.
14. the turbocharger control valve to the mounting on the air cleaner
15. the blue-marked hose/turbocharger control system to the intake manifold.
16. the red-marked hose/turbocharger control system to the charge air pipe.
17. the yellow-marked hose/turbocharger control system to the pressure regulators.
18. the cross stay between the suspension turrets
19. the suspension turret covers.

Clamp the servo hose to the right mounting on the cross stay.

Tighten the pipe screw of the oil pressure pipes to 38 Nm .

Install the drive shaft bearing seat.

Install

1. the right drive shaft. See: «Drive shaft right, replacing»(ref-440352-S00478927422011121400000) .
2. the wheels. See «Installing wheels»(ref-440302-S30067264572011121400000) .
3. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Change the oil and replace the oil filter as necessary.

Check

1. the engine oil level.
2. the servo oil level.
3. the coolant level.

Warm up the engine until the thermostat opens.

Check

1. the engine for leaks.
2. the fluid level in the transmission.
3. the coolant level.

Top up as necessary.

Special tools

See 9512666

See 9512767

See 9995450

See 9995452

See 9995454

See 9995670

See 9995718

See 9995719

See 9995750

See 9995972

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the negative battery cable. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .
3. the right front wheel.

Scheme 193

Raise the car. Remove the splash guard from under the engine.

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Scheme 194

Remove

1. the nuts where the manifold and front exhaust system separate.
2. the first mounting bracket for the exhaust system downstream of the three-way catalytic converter (TWC) from the car body.
3. the front SIPS member from the car body
4. the brake pipe from the holders on the SIPS member.

Press the exhaust system backward so that there is a 60-70 mm gap at the joint after the manifold.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Remove the gaskets.

Seal the openings at the exhaust system.

Scheme 195

Remove

1. the engine stabilizer brace between the suspension turrets
2. the air cleaner (ACL) intake from the connection on the front cover plate.

Undo the clamp holding the plastic intake pipe to the electronic throttle module. Press out the pipe. Leave the pipe in place.

Remove

1. the connector for the mass air flow (MAF) sensor. Disconnect the wiring from the air cleaner (ACL)
2. the control hose for the air preheating damper at the intake manifold
3. the air cleaner (ACL) assembly.

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

First remove the upper timing cover then the front timing cover.

Remove the cover over the ignition coils.

Scheme 196

Remove

1. the clamps that hold the wiring to the rear of the cylinder head
2. the camshaft position (CMP) sensor housing and trigger wheel.
3. the cover at the rear of the intake camshaft
4. the brake vacuum hose from the intake manifold
5. the air pre-heating hose
6. the rear screw in the lower row from the connection between the intake manifold and the cylinder head.

Scheme 197

Remove

1. the upper section of the intake manifold. Install protective plate «9995723»(ref-403953-S12283082452011061000000) .
2. the screws holding the ignition coils and the two ground terminals between the ignition coils. Disconnect the connectors for the variable valve timing solenoid and the engine coolant temperature (ECT) sensor. Lift up and put the ignition coils and wiring to one side. NOTE: Mark up the ignition coils before removal.
3. the upper screw for the transmission dipstick pipe
4. the ground strips between the engine and the firewall
5. the torque rod bracket
6. the upper engine coolant hose for the engine and radiator
7. the dipstick pipe from the intake manifold
8. disconnect the connector for the electronic throttle module.

Releasing The Inlet Pipe For The Coolant Pump

Remove

1. the screw that holds the inlet pipe for the coolant pump on the cylinder block
2. 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.

Scheme 198

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.

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw still. Turn the tensioner eccentric counter-clockwise to 10 o'clock. Use a 6 mm Allen key.

Remove the timing belt.

Install tool 9995452 at the rear of the camshafts.

Remove

1. the center plug for the variable valve timing unit
2. variable valve timing unit center screw. Pull / pry off the variable valve timing unit and timing gear pulley
3. screws holding the timing belt (without the variable valve timing unit) to the camshaft
4. the timing gear pulley
5. tool 999 5452.

Remove

1. the screw for the thermostat housing cable duct
2. screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct
3. screw holding the inner timing cover to the cylinder head.

Removing The Camshaft Cover And Cylinder Head

Remove

1. spark plugs for cylinders 2 and 5. Install tool 999 5454 (x2). Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened.
2. Variable valve timing solenoid
3. screws holding the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head.

Install 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

1. tools 999 5454.
2. the camshaft cover
3. the camshafts.

Lift out the valve lifters. Use a suction cup.

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Remove

1. the intake manifold and gasket
2. the coolant outlet pipe.

Clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the coolant bypass channel
3. the coolant outlet pipe.
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent 1161 440 . Use a fume hood or extractor when using gasket solvent

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Remove

1. the mounting screws for the starter motor. Pull out the starter motor and place to one side
2. the blind cover plug.

Turn the crankshaft slightly clockwise .

Install the crankshaft stop 9995451 . Ensure 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.

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.

Tighten the screws in the following order

1. 20 Nm .

2. 60 Nm .

3. Angle tighten 130° . Use a bevel protractor 9512050 .

When installing a new cylinder head, the valve clearance must be set. See Valve clearance, setting / adjusting .

Lubricate the valve guide wells.

Install all valve lifters

Lubricate the camshaft bearing seats.

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.

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 9512767 . The surface must be completely covered without any excess.

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with the press tools.

Install all the screws and tighten.

Install the variable valve timing solenoid with a new gasket.

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Scheme 199

Use drift 9995450 .

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 turning around the tool's sleeve.

Use camshaft tool 9995452 .

Separate the camshaft adjustment tool into two units.

Note. The camshafts must not be turned more than indicated 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.

Use drift 9995718 for camshaft with variable valve timing unit and drift 9995719 for camshaft without variable valve timing unit.

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Install

1. the screw holding the inner timing cover to the cylinder head
2. the thermostat housing and cable duct. Use a new gasket.
3. the screw for the thermostat housing cable duct.

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Installing The Intake Pipe For The Coolant Pump

Install

1. the inlet pipe for the coolant pump to the cylinder head. Use a new gasket. NOTE: Apply thread sealant, P/N 1161 056, to the screw threads.
2. the screw for mounting the coolant pump inlet pipe to the cylinder block.

Installing The Manifold

Install

1. new gaskets.

Lubricate the studs at the exhaust ports and the flanges on the manifold using paste P/N 116 1408.

Install

1. the manifold
2. the washers and new nuts that hold the manifold onto the cylinder head
3. the heat deflector plate above the manifold

Install

1. the EVAP hose to the intake manifold. Use a new clamp.
2. the crankcase ventilation vacuum hose.
3. the fuel rail. Use new screws.

Install

1. the screw holding the dipstick pipe to the intake manifold
2. the upper engine coolant hose for the engine and radiator. Tighten the clamp
3. the ignition coils according to the earlier markings
4. the screws for the two ground terminals between ignition coils 1 and 2 and 5 and 6
5. the connector for the coolant temperature sensor
6. the connector for the variable valve timing solenoid
7. the torque rod bracket
8. the ground strips between the engine and the firewall
9. the upper screw for the transmission dipstick pipe
10. the upper section of the intake manifold. Use a new gasket. Tighten to 19 Nm .

Install

1. the bracket and screw to the lower row of screws at the mounting for the intake manifold on the cylinder head
2. the air pre-heating hose
3. the brake vacuum hose to the intake manifold
4. the cover at the rear of the exhaust camshaft
5. the camshaft position sensor (CMP) housing and trigger wheel.
6. the clamps that hold the wiring to the rear of the cylinder head

Install

1. the cover over the ignition coils
2. the front timing cover
3. the upper timing cover
4. expansion tank. Connect the connector to the engine coolant level sensor
5. the hose to the expansion tank from the radiator. Tighten the clamp.

Connect the connector to the ABS sensor.

Install

1. the servo oil reservoir. Ensure that the hoses are correctly positioned
2. the air cleaner (ACL) housing assembly.
3. the control hose for the air preheating shutter to the intake manifold
4. the connector to the mass air flow (MAF) sensor. Secure the wiring at the front edge of the air cleaner (ACL) housing.

Connect the throttle body (TB) connector to the engine wiring.

Install

1. the plastic intake pipe between the air cleaner (ACL) housing and the throttle body (TB). Tighten the clamps. Check that the crankcase ventilation hoses are secure
2. the intake pipe for the air cleaner (ACL) housing to the sleeve connector on the front cover plate
3. the engine stabilizer brace between the suspension turrets. Clamp the servo hose to the right mounting on the engine stabilizer brace
4. the plastic nuts for the hatch in the right fender liner
5. the right front wheel. See «Installing wheels»(ref-461711-S34187254862012040200000) .
6. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Replace the oil and oil filter if necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check

1. the engine for leaks
2. the oil level in the transmission
3. the coolant level.

Top up if necessary.

Variable Valve Timing Unit, Checking And Adjusting

Special tools

9995451

9995452

Installing

Installing and adjusting the variable valve timing unit/timing gear pulley on the camshaft

Note. This procedure must be carried out with precision as any deviation could generate a fault symptom.

Installing the crankshaft adjustment tool

Scheme 200

Remove the starter motor mounting screws. Pull out the starter motor and put it aside. Remove the plug of the gauge hole. Rotate the crankshaft slightly clockwise. Install: 9995451 . Make sure that it bottoms against the engine block.

Aligning the crankshaft

Scheme 201

Turn the crankshaft counterclockwise to its stop against the crankshaft adjustment tool. Check that the marking on the crankshaft timing gear pulley aligns with the marking on the oil pump.

Installing the variable valve timing unit on the camshaft

Scheme 202

Note. Oil the center screw before installation.

Press the variable valve timing unit/timing gear pulley onto the camshaft. Install the center screw (1) that holds the variable valve timing unit to the camshaft. Do not tighten yet .

Slacken off, but do not remove the screws (2) which secure the timing gear pulley to the variable valve timing unit.

Position the upper timing cover.

Scheme 203

Turn the timing gear pulley so that the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley's marking is 1 tooth before the marking on the upper timing cover.

Check that the timing gear pulley is still in the limit position in the oval holes.

Tighten the center screw (1) in the VVT unit to 120 Nm .

Check that the variable valve timing unit does not rotate when tightening. Install the center plug and tighten to 35 Nm .

Install the belt pulley on the exhaust camshaft : Install the belt pulley on the intake camshaft with three screws; do not tighten yet .

Check that the markings on the belt pulley and the upper timing cover align.

Installing the timing belt

Install the belt in the following order

1. Fit the timing belt over the pulley on the crankshaft
2. the idler pulley
3. cam wheel, exhaust camshaft
4. water pump
5. belt tensioner.

Scheme 204

Turn the variable valve timing unit clockwise to the stop.

Note. Hold the VVT unit fixed in the limit position clockwise when the belt if fitted.

Check that the markings on the belt pulley and the upper timing cover align.

Install the timing belt (continued)

Scheme 205

Fit the timing belt over the intake camshaft's cam wheel.

Tighten The Timing Belt

Adjust the belt tensioner

Note. This adjustment is done on a cold engine. A suitable temperature is approximately 20° C/68° F.

At higher temperatures (with the engine at operating temperature or a high outside temperatures for example) the indicator is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different engine temperatures.

Tension the timing belt as follows

Scheme 206

Fix the belt tensioner center screw in position and turn the belt tensioner eccentric counterclockwise until the tensioner indicator passes the marked position.

Then turn the eccentric back so that the indicator reaches the marked position in relation to actual temperature.

At the same time, ensure that the center screw remains fixed. At 20° C/68° F, the indicator should be centered in the window.

If the indicator is not in the right position, the adjustment must be repeated.

Note. The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.

1. tighten the screws (2) on the timing gear pulley for the intake camshaft to 10 Nm
2. install the screw missing on the exhaust timing belt pulley
3. tighten the screws on the timing gear pulley for the exhaust camshaft to 20 Nm .

1. the camshaft adjustment tools «9995452»(ref-403953-S02369714572011061000000)
2. the crankshaft stop «9995451»(ref-403953-S26663901482011061000000) .

Install the plug with a new sealing washer. Tighten to 40 Nm .

Checking the markings and belt tension

Scheme 207

1. press the belt to check that the indicator on the tensioner moves easily
2. install the upper timing belt cover
3. turn the crankshaft 2 rotations; check that the markings on the crankshaft and timing gear pulleys align
4. check that the indicator on the belt tensioner is within the marked area.

Special tools

9512050

9512666

9512767

9995450

9995451

9995452

9995454

9995670

9995718

9995719

Removing The Cylinder Head/Gasket

Note. As 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.

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the battery negative lead. See: «Battery, disconnecting»(ref-440259-S31019869382011121400000) .
3. the right front wheel

Remove the upper part of the intake manifold. See Removing The Intake Manifold, Lower Section .

Scheme 208

Remove

1. the cross stay between the suspension turrets.
2. the air cleaner inlet pipe from the connection on the front cover plate.

Remove the connector of the mass air flow sensor.

Mark up and remove the vacuum hoses from the air cleaner housing.

Remove the air cleaner housing assembly.

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

First remove the upper timing cover then the front timing cover.

Remove the cover over the ignition coils.

Scheme 209

Remove

1. the clamps holding the cable harness to the rear edge of the cylinder head.
2. the camshaft position sensor housing and trigger wheel.
3. the cover at the rear edge of the intake camshaft.
4. the air pre-heating hose

Scheme 210

Remove the screws holding the ignition coils and the two ground terminals between the ignition coils.

Unplug the connectors of the variable valve timing solenoid and the coolant temperature sensor.

Lift up and put the ignition coils with cable harness to one side.

Note. Mark up the ignition coils before removal.

Automatic only

Remove the upper screw of the transmission dipstick tube.

Remove

1. the ground strips between the engine and the firewall
2. torque rod bracket.
3. the upper engine coolant hose for the engine and radiator

Scheme 211

Undo the heated oxygen sensor cables from the clips and clamps.

Remove the heat deflector plate above the manifold.

Note. Clean and spray rust removal oil on the free threads before removal.

Remove the nuts from the manifold mounting on the engine.

Pull off and lift up the manifolds.

Remove the gaskets.

Remove

1. the screw that holds the coolant pump inlet pipe onto the cylinder block.
2. 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.

Remove the nuts from the cover on the wing liner.

Position the upper timing cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts align.

Remove the upper timing cover.

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw in a fixed position. Turn the tensioner eccentric counterclockwise to 10 o'clock. Use a 6 mm Allen key.

Remove the timing belt.

Install tool 9995452 at the rear of the camshafts.

Remove

1. the variable valve timing unit center plug.
2. variable valve timing unit center screw. Pull / pry off the variable valve timing unit and timing belt pulley.
3. screws holding the timing belt (without the variable valve timing unit) to the camshaft.
4. the timing belt pulley.
5. tool «9995452»(ref-403953-S02369714572011061000000) .

Remove

1. the screw for the thermostat housing cable duct.
2. the screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct.
3. screw holding the inner timing cover to the cylinder head.

Remove

1. spark plugs for cylinders 2 and 5. Install tool «9995454»(ref-403953-S30108818292011061000000) (x2). Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened.
2. Variable valve timing solenoid.
3. the screws holding the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head.

Install 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

1. tools «9995454»(ref-403953-S30108818292011061000000) .
2. the camshaft cover.
3. the camshafts

Lift out the valve lifters. Use a suction cup.

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Remove

1. the lower part of the intake manifold and the gasket. See «Removing the intake manifold, lower section»(ref-440280-S34594883332011121400000) .
2. coolant outlet pipe.

Clean the gasket faces for

1. the manifold. Check that the studs are tightened.
2. the coolant bypass channel
3. the coolant outlet pipe.
4. intake pipe.
5. engine block.
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a plastic scraper and gasket solvent 116 1440 . Use a fume hood or extractor when using gasket solvent.

Note. For tightening torques, see: Tightening torque .

Note. To ensure that there is no exhaust leakage, see Flanged joint, assembling .

Remove

1. the mounting screws for the starter motor. Pull out the starter motor and place to one side.
2. the blind cover plug.

Turn the crankshaft slightly clockwise .

Install the crankshaft stop 9995451 . Ensure that it bottoms out against the engine block.

Turn the crankshaft counterclockwise until it stops against the crankshaft stop.

Check that the marking on the crankshaft timing belt pulley aligns with the marking on the oil pump.

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.

Tighten the screws in the following order.

1. 20 Nm
2. 60 Nm
3. Angle tighten 130° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

If the cylinder head has been replaced or machined

Install

1. coolant outlet pipe.
2. new gasket with the two center screws in the lower row.
3. the lower part of the intake manifold. See «Installing the intake manifold, lower section»(ref-440280-S32183711062011121400000) .

When installing a new cylinder head, the valve clearance must be set. See Valve clearance, setting / adjusting .

Lubricate the valve guide wells.

Install all valve lifters

Lubricate the camshaft bearing seats.

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.

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 116 1059 to the camshaft cover. The surface must be completely covered without any excess. Use roller 9512767 .

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with the press tools.

Install all the screws and tighten.

Install the variable valve timing solenoid with a new gasket.

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm by turning the drift socket.

Check the variable valve timing unit. See: Variable valve timing unit, checking and adjusting .

Install

1. the coolant pump intake pipe to the cylinder head. Use a new gasket. NOTE: Apply thread sealant, 116 1056 , to the screw threads.
2. the screw for mounting the coolant pump intake pipe to the cylinder block.

Install new gaskets.

Lubricate the threads of the studs and heated oxygen sensors with paste 116 1408 before installation.

Install

1. the manifolds. Use new nuts. Tighten to 25 Nm .
2. the heat deflector plate.
3. the heated oxygen sensors. Tighten to 45 Nm .

Plug in the heated oxygen sensor connectors.

Install the heated oxygen sensor cables with clips and clamps.

Scheme 212

Install

1. the screw holding the engine dipstick tube to the intake pipe.
2. the upper engine coolant hose for the engine and radiator. Tighten the clamp
3. the ignition coils according to the earlier markings
4. the screws for the two ground terminals between ignition coils 1 and 2 and 5 and 6
5. the water temperature sensor connector.
6. the connector for the variable valve timing solenoid.
7. torque rod bracket.
8. the ground strips between the engine and the firewall
9. the upper part of the intake manifold. See «Installing The Fuel Rail»(ref-440280-S04708634382011121400000) .

Automatic only

Install the upper screw of the transmission dipstick tube.

Install

1. the air pre-heating hose
2. the vacuum hoses to the intake pipe.
3. the camshaft position sensor (CMP) housing and trigger wheel
4. the cover at the rear of the exhaust camshaft
5. the clamps holding the cable harness to the rear edge of the cylinder head.

Installing The Exhaust System

Install new gaskets.

Lift up and connect the exhaust system to the manifold.

Install

1. the screws holding the front SIPS member.
2. new nuts at the connection between the exhaust system and manifold.

Tighten the nuts at the exhaust system branching. Tighten the screws on the front and rear SIPS members.

Install

1. the cover over the ignition coils
2. the front timing cover.
3. the upper timing cover
4. expansion tank. Connect the connector to the engine coolant level sensor
5. the hose to the expansion tank from the radiator. Tighten the clamp.

Install

1. the servo oil reservoir. Ensure that the hoses are correctly positioned
2. the air cleaner (ACL) housing assembly
3. the connectors of the mass air flow sensor and electronic throttle module (ETM).

Tighten the clamp holding the hose between the electronic throttle body (ETM) and the air cleaner housing.

Install

1. the air cleaner housing's intake pipe to the connection in the front cover plate.
2. the engine stabilizer brace between the suspension turrets. Clamp the servo hose to the right mounting on the cross stay.
3. the plastic nuts for the hatch in the right fender liner
4. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .
5. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Change the oil and replace the oil filter as necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check

1. the engine for leaks
2. the fluid level in the transmission
3. the coolant level.

Top up as necessary.

Removing The Cylinder Head / Gasket

Note. As 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.

To simplify the text below, the terms turbo 1 and turbo 2 are used. Turbo 1 stands for the turbocharger (TC) for cylinders 1, 2 and 3. Turbo 2 stands for the turbocharger (TC) for cylinders 4, 5 and 6.

Remove

1. the battery negative lead. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .
2. the radiator breather tube by the expansion tank. Install lock grip pliers
3. the right-hand drive shaft. See «Drive shaft right, replacing»(ref-440352-S00478927422011121400000) .
4. the bearing seat for the drive shaft from the cylinder block
5. the pipe screw for the turbocharger oil pressure pipe by the cylinder block.

Disconnect the connectors for the heated oxygen sensors (HO2S). Remove the wiring from the clips and tie straps.

Remove

1. the screw for the mounting for the torque rod on the engine
2. the engine stabilizer brace between the suspension turrets
3. the plastic charge air pipe
4. the plastic intake pipe
5. the pipe screws for the coolant pipes
6. the upper coolant pipe
7. the pipe screws for the oil pressure pipe
8. turbocharger 1 only: The clamp for the vacuum pipe in the turbocharger (TC).

Scheme 213

Remove

1. the intake and charge air pipes from the turbocharger (TC). Seal the openings
2. the heat deflector plates
3. the upper heated oxygen sensors (HO2S).

Scheme 214

Remove the nuts. Disconnect the front exhaust pipe from the turbocharger (TC).

Separate the exhaust system at the flange behind the rear three-way catalytic converter (TWC).

Remove the center SIPS member.

Disconnect the brake pipe from the clips on the front SIPS member.

Remove the screws from the front SIPS member.

Slide the three-way catalytic converter (TWC) (with the heat deflector plate) back and then lower it.

Scheme 215

Remove

1. the pipe screw for the oil pressure outlet on the engine
2. the clamp between the oil pressure pipe / coolant pipe and the intake pipe for the water pump
3. the screws for the oil return line
4. the nuts from the mounting for the turbocharger (TC) to the cylinder head.

Lift off and remove the turbocharger (TC).

Remove

1. the upper engine coolant hose for the engine and radiator
2. the solenoid valve (turbocharger (TC) control system) from the air cleaner (ACL) housing
3. the air cleaner (ACL) intake from the connection on the front cover plate
4. the air cleaner (ACL) assembly.

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

Remove

1. the upper timing cover
2. the front timing cover. For cars with chassis numbers 203779- , see «Removing the front timing cover»(ref-440390-S19360483282011121400000) .
3. the cover over the ignition coils.

Remove

1. the brake vacuum hose from the intake manifold
2. the charge air pipe from the electronic throttle module
3. the dipstick pipe from the intake manifold
4. the pipe screw for the crankcase ventilation connection at the intake manifold
5. the vacuum hose from the charge air by-pass valve
6. the rear screw in the lower row from the connection between the intake manifold and the cylinder head. Remove the bracket
7. the protective cover over the nozzle connectors
8. 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.

Separate the fuel line quick-release connector under the intake manifold, see: Fuel line, lock . Use tool 9512666 .

Carefully put the fuel rail to one side.

Remove the EVAP hose from the intake manifold.

Remove

1. the camshaft position (CMP) sensor housing and trigger wheel
2. the pipe screw for the water-heated crankcase ventilation
3. the clamps for the cable harness - ignition coils and the positive lead.

Remove

1. the screw that holds the inlet pipe for the coolant pump to the cylinder block
2. the two screws at the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

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.

Remove

1. the connectors for the variable valve timing solenoids
2. the connector for the coolant temperature sensor
3. the screws for the ignition coils and the two ground terminals.

Lift up and place the ignition coils and wiring to one side.

Note. Mark up the ignition coils before removal.

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw still. Turn the tensioner eccentric counter-clockwise to 10 o'clock. Use a 6 mm Allen key.

Remove the timing belt.

Removing The Variable Valve Timing Unit / Timing Gear Pulley

Install tool 9995452 at the rear of the camshafts.

Remove

1. the center plugs for the variable valve timing units
2. the center screws for the variable valve timing unit. Pull / work off the variable valve timing units and timing gear pulley
3. tool «9995452»(ref-403953-S02369714572011061000000) .

Remove

1. the screw for the thermostat housing cable duct
2. screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct
3. the screw holding the inner timing cover to the cylinder head.

Remove the spark plugs from cylinders 2 and 5.

Install tools 9995454 (2 pcs.) with 2-3 mm gap to the camshaft cover. Make sure that the screw in the spark plug thread is tightened all the way down.

Remove the variable valve timing solenoids.

Remove all the screws securing the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head.

Install 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

1. tools «9995454»(ref-403953-S30108818292011061000000)
2. the camshaft cover
3. the camshafts.

Lift out the valve lifters. Use a suction cup.

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center as illustrated.

Get help to lift off the cylinder head.

Note. Be very careful so that the contact faces are not damaged.

Remove

1. the intake manifold and gasket
2. the coolant outlet pipe.

Clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the coolant bypass channel
3. the coolant outlet pipe.
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent 116 1440 . Use a fume hood or extractor when using gasket solvent

Installing The Cylinder Head / Gasket

Note. For tightening torques, see: Tightening torque .

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Remove

1. the mounting screws for the starter motor. Pull out the starter motor and place to one side
2. the blind cover plug.

Turn the crankshaft clockwise slightly.

Install the crankshaft stop 9995451 . Ensure 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.

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.

Tighten the screws in the following order

1. 20 Nm
2. 60 Nm
3. Angle-tighten 130° . Use protractor «9512050»(ref-403953-S36645634772011061000000) .

When installing a new cylinder head, the valve clearance must be set. See Valve clearance, setting / adjusting .

Lubricate the valve guide wells.

Install all the valve lifters.

Lubricate the camshaft bearing seats.

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.

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 116 1059 to the camshaft cover. Use roller 9512767 . The surface must be completely covered without any excess.

Note. Make sure that no liquid gasket gets into the oil channels.

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with 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 to 30 Nm .

Use drift 9995450 .

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.

Use camshaft tool 9995452 .

Separate the camshaft adjustment tool into two units.

Note. The camshafts must not be turned more than indicated in the text below, as this can damage valves

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.

Use drift 9995718 .

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.

Install

1. the screw holding the inner timing cover to the cylinder head
2. the thermostat housing and cable duct. Use a new gasket
3. 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".

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting .

Install

1. the trigger wheel
2. the camshaft position (CMP) sensor housing
3. 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

1. the ignition coils according to the earlier markings
2. the connector for the coolant temperature sensor
3. the connectors for the variable valve timing solenoids
4. the screws for the two ground terminals between ignition coils 1 and 2 and 5 and 6.

Install below the intake manifold

1. the starter motor
2. the throttle body (TB) connector to the engine wiring
3. the charge air pipe to the throttle body (TB). Tighten the clamp
4. the control hose to the charge air by-pass valve
5. the brake vacuum hose to the intake manifold
6. the bracket and screw to the lower row of screws at the mounting for the intake manifold on the cylinder head
7. the pipe screws at the underside of the intake pipe for the water heated crankcase ventilation. Tighten to 26 Nm .
8. the dipstick pipe onto the intake manifold.

Install

1. the fuel rail. Use new screws. Tighten to 10 Nm . Press the quick-release connector for the fuel pressure line until it clicks, see also «Fuel line, lock»(ref-461787-S19854223012012040200000) .
2. the clamps holding the injector wiring and the positive cable to the rear edge of the cylinder head
3. the protective cover over the nozzle connectors
4. the upper engine coolant hose to the cylinder head and radiator. Tighten the clamp.

Note. Apply thread sealant 116 1056 on the screws.

Install

1. the inlet pipe for the coolant pump to the cylinder head. Use a new gasket
2. the screw for mounting the coolant pump inlet pipe to the cylinder block.

Installing The Turbocharger (TC)

Lubricate the studs using paste 116 1408 . Avoid skin contact with the paste.

Install the turbocharger (TC) and the new gaskets. Begin with turbocharger 1. Use new nuts. Tighten to 25 Nm .

Install the oil pressure pipe using the pipe screws and new gasket washers. Do not tighten yet.

Scheme 216

Install

1. the screws for the oil return line. Use new gaskets
2. lower coolant pipe. Use new gaskets. Tighten to 26 Nm
3. the pipe screw for the pressure oil outlet on the engine. Use new gaskets. Tighten to 38 Nm
4. the clamps between the oil pressure pipe / coolant pipe and the intake pipe for the water pump
5. the vacuum hose on the pressure regulator (turbocharger (TC) 1)
6. the clamp for the vacuum pipe (turbocharger (TC) 1).

Installing Three-Way Catalytic Converters (TWC) / Front Exhaust Pipe

Note. Avoid skin contact with paste for bolted joints.

Install the catalytic converter with the heat deflector plate. Use a mobile jack and universal plate 9995972 as support.

Use the new nuts and gaskets.

Lubricate the studs using copper paste 116 1408 .

Connect to the rear exhaust pipe. Install the nuts loosely.

Connect the pipes to the engine. Install the nuts loosely.

Press the brake pipe into place on the front SIPS member.

Install the screws for the front SIPS member.

Remove the mobile jack.

Tighten the screws for the front SIPS member and the connection to the rear exhaust pipe.

Install the center SIPS member.

Connect the connector for the rear heated oxygen sensors (HO2S) and clamp the wiring.

Installing The Drive Shaft

Install

1. the bracket for the drive shaft on the engine
2. the right-hand drive shaft. See «Drive shaft right, replacing»(ref-440352-S00478927422011121400000)
3. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Tighten

1. the three-way catalytic converters (TWC) in the turbocharger (TC). Use new nuts. Tighten to 24 Nm
2. the pipe screw for the oil pressure pipe. Tighten to 18 Nm
3. the upper heated oxygen sensors (HO2S). Lubricate the threads using copper paste 116 1408 . Tighten to 45 Nm .

Install the heat deflector plates.

Install the upper coolant pipes. Use new gaskets. Tighten the pipe screw. Tighten to 26 Nm .

Install

1. the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 2)
2. the intake and charge air pipes
3. the hose from the pressure regulator to the T piece (turbocharger (TC) 2)
4. the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 1).

Clamp the wiring for the heated oxygen sensors (HO2S).

Install

1. the torque rod bracket
2. the upper screw securing the automatic transmission dipstick pipe to the engine. Tighten the lower screw
3. the ground lead between the firewall and the torque rod bracket
4. the ground lead between the right-hand frame member and the cylinder head.

Install

1. the cable duct on the inside of the right suspension turret
2. the front timing cover. For cars with chassis numbers 203779- , see «Installing the front timing cover»(ref-440390-S09737832492011121400000) .
3. expansion tank. Connect the connector to the coolant level sensor
4. 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.

Install the servo reservoir. Ensure that the hoses are correctly positioned.

Install

1. the upper timing cover
2. the cover over the ignition coils
3. 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
4. the plastic charge air pipe over the engine. Tighten the clamps and mounting screws
5. the hose between the charge air cooler (CAC) and the plastic charge air pipe over the engine. Tighten the clamps
6. the crankcase ventilation hose to the PTC resistor in the plastic intake pipe over the engine. Use a new clamp
7. the connector for the PTC resistor
8. the protective cover over the PTC resistor
9. the EVAP hose to the plastic intake pipe
10. the outlet pipe from the by-pass valve to the plastic intake pipe. Tighten the clamp
11. the air cleaner (ACL) assembly. Press the air cleaner (ACL) intake pipe into place on the connection on the front cover plate
12. the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp
13. the connector to the mass air flow (MAF) sensor. Clamp the cable to the front of the air cleaner (ACL)
14. the turbocharger (TC) control valve to the mounting on the air cleaner (ACL)
15. the blue marked hose and the turbocharger (TC) control system to the intake manifold
16. the red marked hose and turbocharger (TC) control system to the charge air pipe
17. the yellow marked hose and turbocharger (TC) control system to the pressure regulators
18. the cross stay between the suspension turrets
19. the suspension turret covers.

Clamp the servo hose to the right mounting on the engine stabilizer brace.

Connect the battery negative lead. Also read Battery, disconnecting .

Replace the oil and oil filter if necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check

1. the engine for leaks
2. the oil level in the transmission
3. the coolant level.

Top up if necessary.

Special tools

9512666

9512767

9995450

9995452

9995454

9995670

9995718

9995719

9995750

9995972

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the negative battery lead. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .
3. the right front wheel.

Remove

1. the 8 nuts where the front section of the exhaust system connects with the manifold.
2. the first mounting bracket for the exhaust system downstream of the catalytic converter from the body.
3. the front SIPS member from the body.
4. the brake pipe from the holders on the SIPS member.

Press the exhaust system backward so that there is a 60-70 mm gap at the joint after the manifold.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Remove the gaskets.

Seal the openings at the exhaust system.

Remove

1. the cross stay between the suspension turrets.
2. the air cleaner inlet pipe from the connection on the front cover plate.

Undo the clamp holding the plastic intake pipe to the electronic throttle module. Press out the pipe. Leave the pipe in place.

Remove

1. the connector for the mass air flow (MAF) sensor. Disconnect the wiring from the air cleaner (ACL)
2. the control hose for the air preheating damper at the intake manifold
3. the air cleaner assembly.

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

First remove the upper timing cover then the front timing cover.

Remove the cover over the ignition coils.

Remove

1. the clamps that hold the wiring to the rear of the cylinder head
2. the camshaft position (CMP) sensor housing and the trigger wheel.
3. the cover at the rear of the intake camshaft.
4. the brake vacuum hose from the intake manifold.
5. the air pre-heating hose
6. the rear screw in the lower row from the connection between the intake manifold and the cylinder head.

Remove

1. the upper section of the intake manifold. Install protective plate «9995723»(ref-403953-S12283082452011061000000) .
2. the screws holding the ignition coils and the two ground terminals between the ignition coils. Disconnect the connectors for the variable valve timing solenoid and the engine coolant temperature (ECT) sensor. Lift up and put the ignition coils and wiring to one side. NOTE: Mark up the ignition coils before removal.
3. the upper screw for the transmission dipstick pipe
4. the ground strips between the engine and the firewall
5. the torque rod bracket.
6. the upper engine coolant hose for the engine and radiator
7. the dipstick pipe from the intake manifold
8. disconnect the connector for the electronic throttle module.

Remove the mounting screws from the fuel rail.

Spray universal oil or similar around the injector connectors on the intake manifold.

Gently work the fuel rail and injectors loose.

Separate the fuel line quick-release connector under the intake manifold. Use tool 9512666 .

Carefully put the fuel rail to one side.

Remove

1. the EVAP hose from the intake manifold.
2. the crankcase ventilation vacuum hose.

Removing The Manifold

Remove

1. the heat deflector plate above the manifold
2. the nuts and washers holding the manifold to the cylinder head
3. the manifold and gaskets.

Remove

1. the screw that holds the coolant pump inlet pipe onto the cylinder block.
2. 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.

Remove the nuts from the cover on the wing liner.

Position the upper timing cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts align.

Remove the upper timing cover.

Compressing The Tensioner / Damping Unit

Assemble tool 9995750 . Install the tool between the lever pulley and the lifting lug at the servo pump.

Slacken off the screw in the tool so that there is clearance of approximately 10 mm between the screw head and the tool.

Allow the tool spring to compress the tensioner / damping unit.

Install tool 9995452 at the rear of the camshafts.

Check that the tensioner / damper unit has been compressed.

Remove the timing belt.

Remove

1. the variable valve timing unit center plug.
2. variable valve timing unit center screw. Pull / pry off the variable valve timing unit and timing belt pulley.
3. screws holding the timing belt (without the variable valve timing unit) to the camshaft.
4. the timing belt pulley.
5. tool 999 5452.

Lift out the valve lifters. Use a magnet or suction cup.

Note. Keep the tappets in an oil-filled container to avoid self-drainage.

Remove

1. the intake manifold and gasket.
2. the coolant outlet pipe.

Note. Work very carefully to avoid damaging the contact faces.

Clean the gasket faces for

1. the manifold. Check that the studs are tightened.
2. the coolant bypass channel
3. the coolant outlet pipe.
4. intake manifold.
5. engine block.
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent 1161 440 . Use a fume hood or extractor when using gasket solvent

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Remove

1. the mounting screws for the starter motor. Pull out the starter motor and place to one side.
2. the blind cover plug.

Turn the crankshaft slightly clockwise .

Install the crankshaft stop 9995451 . Ensure that it bottoms out against the engine block.

Turn the crankshaft counterclockwise until it stops against the crankshaft stop.

Check that the marking on the crankshaft timing belt pulley aligns with the marking on the oil pump.

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.

Tighten the screws in the following order.

1. 20 Nm .

2. 60 Nm .

3. Angle tighten 130° . Use a bevel protractor 9512050 .

Lubricate the valve guide wells.

Install all valve lifters

Lubricate the camshaft bearing seats.

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.

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 9512767 . The surface must be completely covered without any excess.

Note. Make sure that no liquid gasket gets into the oil channels.

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with the press tools.

Install all the screws and tighten.

Install the variable valve timing solenoid with a new gasket.

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Use drift 9995450 .

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 turning around the tool's sleeve.

Use camshaft tool 9995452 .

Separate the camshaft adjustment tool into two units.

Note. The camshafts must not be turned more than indicated 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 counterclockwise 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.

Use drift 9995718 for camshaft with variable valve timing unit and drift 9995719 for camshaft without variable valve timing unit.

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Install

1. the screw holding the inner timing cover to the cylinder head.
2. the thermostat housing and cable duct. Use a new gasket
3. the screw for the thermostat housing cable duct.

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Install

1. the coolant pump intake pipe to the cylinder head. Use a new gasket. NOTE: Apply thread sealant, P/N 1161 056, to the screw threads.
2. the screw for mounting the coolant pump intake pipe to the cylinder block.

Install

1. new gaskets.

Lubricate the studs at the exhaust ports and the flanges on the manifold using paste P/N 116 1408.

Install

1. the manifold
2. the washers and new nuts that hold the manifold onto the cylinder head
3. the heat deflector plate above the manifold

Install

1. the EVAP hose to the intake manifold. Use a new clamp
2. the crankcase ventilation vacuum hose.
3. the fuel rail. Use new screws.

Install

1. the screw holding the dipstick pipe to the intake manifold
2. the upper engine coolant hose for the engine and radiator. Tighten the clamp
3. the ignition coils according to the earlier markings
4. the screws for the two ground terminals between ignition coils 1 and 2 and 5 and 6
5. the connector for the coolant temperature sensor
6. the connector for the variable valve timing solenoid.
7. the torque rod bracket.
8. the ground strips between the engine and the firewall
9. the upper screw for the transmission dipstick pipe
10. the upper section of the intake manifold. Use a new gasket. Tighten to 19 Nm .

Install

1. the bracket and screw to the lower row of screws at the mounting for the intake manifold on the cylinder head.
2. the air pre-heating hose
3. the brake vacuum hose to the intake manifold.
4. the cover at the rear of the exhaust camshaft
5. the camshaft position sensor (CMP) housing and trigger wheel
6. the clamps that hold the wiring to the rear of the cylinder head

Install

1. the cover over the ignition coils
2. the front timing cover.
3. the upper timing cover
4. expansion tank. Connect the connector to the engine coolant level sensor
5. the hose to the expansion tank from the radiator. Tighten the clamp.

Connect the connector to the ABS sensor.

Install

1. the servo oil reservoir. Ensure that the hoses are correctly positioned
2. the air cleaner (ACL) housing assembly
3. the control hose for the air preheating shutter to the intake manifold
4. the connector to the mass air flow (MAF) sensor. Secure the wiring at the front edge of the air cleaner (ACL) housing.

Connect the throttle body (TB) connector to the engine wiring.

Install

1. the plastic intake pipe between the air cleaner (ACL) housing and the throttle body (TB). Tighten the clamps. Check that the crankcase ventilation hoses are secure
2. the intake pipe for the air cleaner (ACL) housing to the sleeve connector on the front cover plate
3. the engine stabilizer brace between the suspension turrets. Clamp the servo hose to the right mounting on the cross stay.
4. the plastic nuts for the hatch in the right fender liner
5. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .
6. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Change the oil and replace the oil filter as necessary.

Check

1. the engine oil level.
2. the servo oil level.
3. the coolant level.

Warm up the engine until the thermostat opens.

Check

1. the engine for leaks.
2. the fluid level in the transmission.
3. the coolant level.

Top up as necessary.

Auxiliaries Belt / Belt Tensioner, Replacing

Special tools

9512050

Scheme 217

Lift up the servo reservoir and place on top of the engine.

Note. Ensure that no oil leaks out of the ventilation hole in the cover.

Use a 15 mm wrench and turn clockwise as far as possible to relieve the load.

Lift off the belt.

Scheme 218

Remove the mounting screws for the belt tensioner from the auxiliaries belt bracket.

Remove the belt tensioner.

Install new pulley. Tighten to 25 Nm .

Scheme 219

Raise the car and remove

1. the right front wheel
2. the plastic nuts from the cover in the fender liner
3. the vibration damper. Use the crankshaft center nut as a counterhold
4. the auxiliaries belt.

Install

1. new auxiliaries belt
2. the vibration damper. Tighten to 35 Nm . Angle-tighten 50° . Use the crankshaft center nut as a counterhold. Use bevel protractor «9512050»(ref-403953-S36645634772011061000000)
3. the plastic nuts from the cover in the fender liner
4. the wheel. See «Installing wheels»(ref-461711-S34187254862012040200000) .

Scheme 220

Use a 15 mm wrench and turn clockwise as far as possible to relieve the load.

Install the belt in the following order

1. Crankshaft
2. Air conditioning (A/C) compressor
3. Belt tensioner
4. Generator (GEN)
5. Servo pump.

Install the servo reservoir.

Test the function.

Removing The Front Camshaft Seal

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Replacing The Rear Camshaft Seal

See Removing/Installing the rear camshaft seal .

Remove the timing belt from the timing gear pulley for the camshafts. See Replacing the timing belt .

Check the tensioner and idler pulleys. See Replacing the timing belt .

Remove camshaft position (CMP) sensor housing and the trigger wheel.

Remove the cover at the rear edge of the camshaft.

Scheme 221

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one. Remove the plug from the front edge of the variable valve timing unit (Tx55).

Remove the center screw from the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing

Remove the screws. Remove the timing gear pulley.

Scheme 222

Carefully press in tool 9995651 between the seal and the camshaft. Pry out the seal.

Note. The purpose of the "Installing the VVT unit/timing gear pulley" section described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Note. For tightening torques, see Tightening torque .

Cleaning

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Scheme 223

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. For camshafts with variable valve timing

Use drift 9995718 .

Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out. for camshafts without variable valve timing

Use drift 9995719 .

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Install

1. the starter motor. Tighten screws at gearbox. Tighten. See «Tightening torque»(ref-440295-S16446937762011121400000)
2. the screw at the support bracket for the starter motor. Tighten
3. the trigger wheel. Tighten the screw
4. the camshaft position (CMP) sensor housing. Tighten the screws
5. the new cover in the rear edge of the camshaft
6. the intake pipe between the charge air cooler (CAC) and the electronic throttle module (ETM).

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the plastic nuts for the cover in the right-hand wing liner
2. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Scheme 224

Install

1. front timing cover. Tension the auxiliaries belt. Check that it is correctly positioned on all pulleys
2. the expansion tank
3. the hose between the expansion tank and the radiator. Remove the lock grip pliers
4. the servo reservoir
5. the upper timing cover.

Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp. Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC). Tighten the hose clamps.

Scheme 225

Install

1. the engine stabilizer brace. Tighten the screws
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten
3. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Check and top up if required

1. coolant level
2. the servo fluid level.

Test drive the engine.

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace
4. the air cleaner (ACL) cover. Place it to one side
5. the camshaft position (CMP) sensor housing and the trigger wheel.

Scheme 226

Pull out the seal. Use puller 9995919 . Use emery cloth 951 1024 to clean the shaft journal and mating surface.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 9995450 .

Note. The seal is normally positioned at the same level as the internally bevelled edge. If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm : Turn the drift socket.

Note. For tightening torques, see Tightening torque .

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the air cleaner (ACL) cover
4. the engine stabilizer brace. Tighten the screws
5. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten.

Test drive the engine.

Replacing The Timing Belt

Special tools

9995433

9995456

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.

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace.

Applies only to B6xx4T engines

Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and turbocharger (TC). Put them to one side.

Remove the clamp from the intake manifold for the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the bulkhead.

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

Remove the upper timing belt cover.

Remove the front timing belt cover.

For cars with chassis numbers 203779- , see Timing cover front, replacing .

Lift up the servo reservoir and place it on top of the engine.

Note. Ensure that the power steering oil 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.

Raise the car.

Remove

1. the right front wheel
2. the plastic nuts on the cover in the wing liner.

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.

Turn the crankshaft a further 1/4 turn clockwise.

Then turn back counter-clockwise until the markings correspond.

Remove the upper timing belt cover.

Remove the 4 vibration damper screws. Counterhold the crankshaft central nut.

Remove

1. the vibration damper
2. the auxiliaries belt
3. the belt cover behind the crankshaft pulley for the auxiliaries belt.

Spray universal oil or similar around the rubber sleeve on the underside of the oil pump.

Remove the rubber sleeve.

Slacken off the belt tensioner

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw still. Turn the tensioner eccentric counter-clockwise using a 6 mm Allen key. Turn to 10 o'clock.

Unhook and remove the timing belt.

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

Check bearing wear

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".

Scheme 227

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

Install the belt in the following order

1. crankshaft
2. the idler pulley
3. intake cam
4. exhaust cam
5. water pump
6. tension pulley.

Note. The variable valve timing unit on B6304S does not have a return spring. The unit is easily dislodged when reinstalling the timing belt.

Scheme 228

This adjustment is done with a cold engine. 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 farther to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be in tension between the intake camshaft pulley, the idler pulley and the crankshaft.

Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position.

Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.

Hold the eccentric secure. Tighten the center screw to 25 Nm.

Check that the indicator is in the correct position.

Scheme 229

Press the belt to check that the indicator on the tensioner moves easily.

Install the upper timing belt cover.

Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond.

Check that the indicator on the belt tensioner is within the marked area.

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the rubber sleeve on the underside of the oil pump
2. the vibration damper. Use new screws . Tighten to 35 Nm . Angle-tighten 50° . Use the crankshaft center nut as a counterhold
3. the plastic nuts for the cover in the right-hand wing liner
4. the right front wheel. See «Installing wheels»(ref-461711-S34187254862012040200000) .

Lower the car.

1. the front timing belt cover. For cars with chassis numbers 203779- , see «Installing the front timing cover»(ref-440390-S09737832492011121400000) .

Tension the auxiliaries belt.

1. the expansion tank
2. the hose between the expansion tank and the radiator. Remove the lock grip pliers
3. the servo reservoir
4. the upper timing belt cover.

Applies only to B6xx4T engines

Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp.

Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC).

Tighten the hose clamps.

1. the engine stabilizer brace. Tighten to 50 Nm
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten to 80 Nm .

Check and top up if required

1. coolant level
2. the servo fluid level.

Test drive the engine.

Scheme 230

Applies only to B6XX4T

Remove the crankcase ventilation pipe from the intake manifold. Start with the cover.

Remove the plastic hoses between the turbocharger (TC) / charge air cooler and the air cleaner (ACL) / turbocharger (TC). Place them to one side and seal the openings.

Remove the clamp for the intake manifold at the turbocharger (TC) for cylinders 1, 2 and 3. Detach the upper section of the pipe by turning it towards the firewall.

Scheme 231

Remove

1. the upper timing belt cover. Disconnect the control valve connector.

Note. Clean the area around the variable valve timing (VVT) valve thoroughly to avoid contaminated oil entering the ducts / the variable valve timing (VVT) valve.

1. the screws holding the valve
2. the control valve and the gasket.

Installing The Variable Valve Timing (VVT) Control Valve

Clean the gasket faces. Note the cleanliness requirements above.

Install a new gasket .

Install a new control valve. Tighten the control valve crosswise. Tighten to 10 Nm

Connect the connector.

Install the upper timing belt cover.

Applies only to B6xx4T

Install the seals.

Install the plastic hoses between the turbocharger (TC) / charge air cooler and the air cleaner (ACL) / turbocharger (TC).

Tighten all the hose clamps.

See Auxiliaries belt / belt tensioner, replacing

Camshaft Seal/Variable Valve Timing (VVT) Unit, Replacing

Special tools

See 9995452

See 9995651

See 9995718

See 9995719

See 9995451

See 9995919

See 9995450

See 9995750

Note. As 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.

Removing The Rear Camshaft Seal

See Removing/Installing the rear camshaft seal .

Removing The Front Camshaft Seal / Variable Valve Timing Unit

1. Remove the timing belt from the timing gear pulley for the camshafts. See «Replacing the timing belt»(ref-440293-S07193705732011121400000)
2. Check the tensioner and idler pulleys. See «Replacing the timing belt»(ref-440293-S07193705732011121400000)
3. Remove the camshaft position (CMP) sensor housing and the trigger wheel
4. Remove the cover at the rear edge of the camshaft.

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one.

Remove the plug from the front edge of the variable valve timing unit (Tx55). Remove the center screw from the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing

Remove the screws and the timing gear pulley.

Carefully press in tool 9995651 between the seal and the camshaft.

Pry out the seal.

Note. The purpose of the section "Installing the VVT unit/timing gear pulley", described here, is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Note. For tightening torques, see: Tightening torque .

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal.

For camshafts with variable valve timing: Use drift 9995718 .

Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out.

For camshafts without variable valve timing: Use drift 9995719 .

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Install

1. the starter motor. Tighten screws at gearbox. Tighten. See «Tightening torque»(ref-440295-S16446937762011121400000)
2. the screw at the support bracket for the starter motor. Tighten
3. the trigger wheel. Tighten the screw
4. the camshaft position (CMP) sensor housing. Tighten the screws
5. a new cover at the rear edge of the camshaft.

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the plastic nuts for the cover in the right-hand wing liner
2. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Install

1. front timing cover. Tension the auxiliaries belt. Check that it is correctly positioned on all pulleys
2. the expansion tank
3. the hose between the expansion tank and the radiator. Remove the lock grip pliers
4. the servo reservoir
5. the upper timing cover.

Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp. Install the plastic hoses between the turbocharger (TC) and the charge air cooler (CAC) and between the air cleaner (ACL) and the turbocharger (TC). Tighten the hose clamps

1. the engine stabilizer brace. Tighten the screws
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten
3. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Check and top up if required

1. coolant level
2. the servo fluid level.

Test drive the engine.

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace
4. the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
5. the air cleaner (ACL) cover. Place it to one side
6. the camshaft position (CMP) sensor housing and the trigger wheel.

Pull out the seal. Use puller 9995919 .

Use emery cloth 951 1024 to clean the shaft journal and mating surface.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 9995450 .

Note. The seal is normally positioned at the same level as the internally bevelled edge. If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm : Turn the drift socket.

For tightening torques, see: Tightening torque .

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the air cleaner (ACL) cover
4. the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
5. the engine stabilizer brace. Tighten the screws
6. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten.

Final check

Test drive the engine.

Special tools

9995433

9995456

Remove

1. the screw for the torque rod mounting at the bracket on the engine.
2. the screws at the cross rod mounting to the suspension turret.
3. the cross stay.

Applies only to B6xx4T

Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) / turbocharger (TC). Place them to one side.

Remove the clamp for the intake manifold at the turbocharger (TC) for cylinders 1, 2 and 3 and turn the upper section of the pipe towards the firewall.

Scheme 232

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

Remove the upper camshaft belt cover.

Remove the front camshaft belt cover.

Lift up the servo reservoir and place it on top of the engine.

Note. Ensure that the power steering oil 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.

Raise the car.

Remove

1. the right front wheel.
2. the plastic nuts from the cover in the fender liner.

Install the upper camshaft belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.

Turn the crankshaft a further 1/4 turn clockwise.

Then turn back counter-clockwise until the markings correspond.

Remove the upper camshaft belt cover.

Remove the 4 vibration damper screws. Counterhold the crankshaft central nut.

Remove

1. the vibration damper.
2. the auxiliaries belt.

Install counterhold 9995433 .

1. the crankshaft center nut. Remove counterhold 999 5433.
2. the pulley for the auxiliaries belt.

Scheme 233

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

First remove the upper screw for the tensioner / damping unit.

Then remove the lower screw.

Turn the tensioner / damping unit so that the cylinder comes free.

Remove

1. the lower screw.
2. the tensioner / damping unit.
3. the timing belt.

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

Note. The crankshaft or camshafts must not be rotated while the timing belt is removed.

Checking The Tensioner And Idler Pulleys

Spin the pulleys and listen for noise from the bearings. Check that the pulley surfaces to the belt are clean and smooth.

Check the tension pulley lever and mounting.

The tension pulley lever. Torque 30 Nm. The idler pulley, tightening torque 25 Nm.

Scheme 234

Check that there is no visible leakage.

Press the tensioner/damping unit together with tool 9995456 . Position the tensioner/damping unit in the tool and screw the tool center nut to the bottom. Wait until it is compressed and then install a lock pin in the piston.

Note. The tensioner damping unit must be replaced if there is leakage or there is no resistance when pushed in or if it cannot be pushed in.

Install the tensioner/damping unit. Tighten to 25 Nm .

Scheme 235

Install the belt in the following order

1. crankshaft.
2. idler pulley.
3. intake cam.
4. exhaust cam.
5. water pump.
6. tension pulley.

Note. The variable valve timing unit on B6304S does not have a return spring. The unit is easily dislodged when reinstalling the timing belt.

Scheme 236

Pull the lock pin out of the tensioner / damping unit.

Install the pulley for the auxiliaries belt.

Install the crankshaft center nut.

Turn the crankshaft two revolutions and check that the markings on the crankshaft and camshaft pulleys align.

Install counterhold 9995433 tighten the crankshaft's center nut to 300 Nm .

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the vibration damper with new screws . Tighten to 35 Nm . Angle-tighten 50° . Use the crankshaft center nut as a counterhold.
2. the plastic nuts in the cover in the right fender liner.
3. the right front wheel. See «Installing wheels»(ref-461711-S34187254862012040200000) .

Lower the car.

1. the front camshaft belt cover.

Tension the auxiliaries belt.

1. the expansion tank
2. the hose between the expansion tank and the radiator. Remove the lock grip pliers.
3. the servo reservoir.
4. the upper camshaft belt cover.

Applies only to B6xx4T

Turn the intake pipe for the turbocharger for cylinders 1, 2 and 3 into place and tighten the clamp.

Install the plastic hoses between the turbocharger (TC) / charge air cooler and the air cleaner (ACL) / turbocharger (TC).

Tighten the hose clamps.

1. the cross stay. Use new screws . Tighten to 50 Nm .
2. a new screw for the torque rod mounting at the bracket on the engine. Tighten to 80 Nm .

Check and top up if required

1. the coolant level.
2. the servo fluid level.

Test-run the engine.

Variable Valve Timing Solenoid, Replacing

See Variable valve timing solenoid, replacing

See Auxiliaries belt / belt tensioner, replacing

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

See Removing/Installing the rear camshaft seal .

Remove the timing belt from the timing gear pulley for the camshafts. See Replacing the timing belt .

Check the tensioner and idler pulleys. See Replacing the timing belt .

Remove camshaft position (CMP) sensor housing and the trigger wheel.

Remove the cover at the rear edge of the camshaft.

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one. Remove the plug from the front edge of the variable valve timing unit (Tx55).

Remove the center screw from the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing

Remove the screws. Remove the timing gear pulley.

Carefully press in tool 9995651 between the seal and the camshaft. Pry out the seal.

Note. The purpose of the "Installing the VVT unit/timing gear pulley" section described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Note. For tightening torques, see Tightening torque .

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. For camshafts with variable valve timing

Use drift 9995718 .

Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out. for camshafts without variable valve timing

Use drift 9995719 .

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting .

Installing The Starter Motor

Install

1. the starter motor. Tighten screws at gearbox. Tighten. See «Tightening torque»(ref-440295-S16446937762011121400000)
2. the screw at the support bracket for the starter motor. Tighten NOTE: Note The support bracket is withdrawn during model year 2002.
3. the trigger wheel. Tighten the screw
4. the camshaft position (CMP) sensor housing. Tighten the screws
5. a new cover at the rear edge of the camshaft.

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the plastic nuts for the cover in the right-hand wing liner
2. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Install

1. front timing cover. Tension the auxiliaries belt. Check that it is correctly positioned on all pulleys
2. the expansion tank
3. the hose between the expansion tank and the radiator. Remove the lock grip pliers
4. the servo reservoir
5. the upper timing cover.

Install

1. the engine stabilizer brace. Tighten the screws
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten
3. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Check and top up if required

1. coolant level
2. the servo fluid level.

Test drive the engine.

Remove

1. the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
2. the air cleaner (ACL) cover. Place it to one side
3. the camshaft position (CMP) sensor housing and the trigger wheel.

Pull out the seal. Use puller 9995919 . To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 9995450 .

Note. The seal is normally positioned at the same level as the internally bevelled edge. If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm : Turn the drift socket.

Note. For tightening torques, see: Tightening torque .

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the air cleaner (ACL) cover
4. the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
5. the engine stabilizer brace. Tighten the screws
6. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten.

Test drive the engine.

See Replacing the timing belt

Replacing The Variable Valve Timing Solenoid

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Preparations

Applies only to B6xx4T

Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and the turbocharger (TC).

Put them to one side.

Slacken off the clamp for the intake manifold at the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the manifold towards the firewall.

Scheme 237

Remove the upper timing belt cover.

Note. Clean the area around the variable valve timing (VVT) solenoid thoroughly to avoid contaminated oil entering the ducts / the variable valve timing (VVT) unit.

Remove

1. the connector for the check valve
2. the screws holding the valve
3. the control valve and the gasket.

Installing The Variable Valve Timing Solenoid

Clean the gasket faces. Note the cleanliness requirements above.

Install a new gasket.

Install

1. a new check valve Tighten the control valve crosswise. Tighten to 10 Nm
2. the connector
3. the upper timing belt cover.

Applies only to B6xx4T

Turn back the intake manifold for the turbocharger (TC) for cylinders 1, 2, 3 and tighten the clamp.

Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC).

Tighten the hose clamps.

Bushing Sub-Frame, Replacing

Special tools

See 9995716

See 9995460

See 9995717

See 9995589

See 9995352

See 9995457

See 9995567

See 9995575

See 9995576

See 9512564

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Scheme 238

Scheme 239

Install lifting tools 9995716 and lifting hooks 9995460 .

Lift the engine to relieve the load on the engine pads.

Scheme 240

Slacken off the hose clamps for all the charge air pipes (5X).

Remove the 2 screws from the charge air pipe on the intake manifold.

Separate all the charge air pipe. Leave the pipes lying on the spark plug cover.

Scheme 241

Remove

1. the screws for the spark plug cover
2. the cover
3. the ground strip screw.

Applies only to turbocharged engines

Remove the screws.

Lift up the delivery lines. Remove the spark plug cover.

Scheme 242

Remove the 2 screws at the engine mounting.

Install lifting lug 9995717 .

Scheme 243

Remove

1. the front wheels
2. the splash guard under the engine.

Scheme 244

1. the air baffle.

Scheme 245

1. the screw for the cable duct
2. the control module box evacuation pipe mounting from the sub-frame.

Scheme 246

Remove the lower screw for the front engine pad.

Scheme 247

Remove both the nuts retaining the lower torque rod.

Scheme 248

Slacken off the right lower front part of the fender liner.

Remove the plastic nuts on the fender liner.

Remove the cover plate.

Bend out the fender liner.

Scheme 249

Remove the screws holding the right-hand engine mounting in the engine.

Marking The Left-Hand Rear Bushing

Note. The left-hand rear bushing on the sub-frame is a different version to the other three bushings. The hole in the center of the bushing is oval. The oval must be positioned lengthways to the car, as illustrated.

Scheme 250

Install the hydraulic tool and press sleeve as illustrated.

Press the bushings into the sub-frame.

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Scheme 251

Lifting The Sub-Frame

Lift the sub-frame up completely.

At the same time locate the mounting screws for the steering gear on the sub-frame.

Install the sub-frame brackets loosely together with the washers.

Install the four screws for the sub-frame. Use new screws. Do not tighten yet .

First tighten the screws on the left side of the sub-frame. Tighten to 105 Nm . Angle tighten 120° . Then tighten the right-hand side to the same values as the left side.

Finally tighten the screws for the brackets on both sides. Tighten to 50 Nm .

Install the engine block heater (if applicable) on the left front mounting for the sub-frame.

Installing The Nuts And Screw For The Steering Gear

Install

1. the four nuts and screws holding the steering gear. Use new nuts and new screws. Tighten to 50 Nm .

Installing The Delivery Line From The Steering Gear

Install the delivery line from the steering gear on the mountings on the sub-frame. Install any fuel line for the engine block heater.

Installing The Screws For The Engine Mounting To The Engine

Reinstall the screws holding the engine mounting to the engine. Tighten to 35 Nm . Angle-tighten 90° .

Note. Use new screws.

Installing The Protective Plate

Install

1. the right lower front section of the fender liner
2. the protective plate
3. the plastic nuts for the protective plate.

Scheme 252

Install the front engine pad screw. Tighten to 50 Nm .

Installing The Air Intake Cover

Install

1. the screw for the cable duct
2. the evacuation pipe on the sub-frame.

1. the air baffle.

Installing The Protective Cover

Install the splashguard under the engine.

Removing The Lifting Tools

Lower the car.

Remove the lifting tools.

Install the wheels. See Installing wheels .

Removing The Lifting Lug And The Lifting Hook From The Engine And The Car (6- Cylinder Engines Only)

Remove the lifting lug from the engine. Reinstall the screws. Tighten to 50 Nm .

Reinstall the spark plug cover. Tighten the screws. Tighten to 10 Nm .

Install the ground strip. Tighten to 10 Nm .

Lift up the delivery lines. Install the spark plug cover ( applies only to turbo cars ).

Installing All Charge Air Pipes (Only 6-Cylinder Turbo Engines)

Applies only to turbo cars

Connect all the charge air pipes to each other.

Tighten the hose clamps.

Install the screws for the charge air pipe in the intake manifold. Tighten to 10 Nm .

See Bushing sub-frame, replacing

Replacing Front Engine Pad

Special tools

9995972

9512050

Remove

1. the torque rod mounting screw at the bracket on the engine.
2. screws at cross rod mounting to suspension turret.
3. cross member
4. intake manifold between air cleaner (ACL) and electronic throttle module (ETM). (Applies only to B6xx4S).
5. the front engine pad upper nut.

Raise car and remove

1. left front wheel.
2. the splash guard under the engine.
3. the screw at the lower torque rod mounting for the bracket on the transmission.
4. the engine pad lower screw.

Scheme 253

1. the screws at the front cross member (x4).
2. the exhaust pipe mounting screws in the front cross member.
3. brake pipe from its holder in the member.

Scheme 254

1. the exhaust flange nuts and gaskets.

1. the nuts at the rear cross member holding the exhaust pipe to the member.

Lift the three-way catalytic converter (TWC) and exhaust pipe backwards

Lift up the exhaust pipe mounting from the rear member. Use a jimmy bar. Pull the exhaust pipe backwards so that the mounting ends up behind the member.

Move the three-way catalytic converter (TWC) and exhaust system backward.

Scheme 255

Remove the screws for the sub-frame bracket holding the heated oxygen sensor (HO2S) cable.

Scheme 256

Position a mobile jack with universal plate 9995972 under oil pan long, as far to the left as possible.

Note. Dry off the oil pan and the universal plate.

Check that the plate does not catch in the sub-frame.

Carefully lift up the engine so that the engine pad can be replaced.

Install a new screw in the engine pad lower mounting. Do not tighten yet.

Carefully lower the engine.

Note. Ensure that engine pad locating pin locates correctly.

Remove the mobile jack.

Lift up the exhaust pipe at the rear member. Move the exhaust system forwards.

Install

1. the rubber mounting in the cross member.
2. the nuts on the rear mounting. Tighten to 25 Nm (18.4 lb. ft) .

1. the three-way catalytic converter (TWC) and exhaust pipe on the engine. Use new nuts and gaskets .
2. exhaust manifold nuts. Tighten to 25 Nm (18.4 lb. ft) .

1. the screws for the bracket.
2. the connectors in the sub-frame.

1. exhaust pipe mounting screws. Tighten to 10 Nm (7.4 lb. ft) .
2. the brake pipe in its holders.
3. the cross member screws. Tighten to 25 Nm (18.4 lb. ft) .

Scheme 257

Install a new screw in the lower torque rod. Tighten to 35 Nm (25.8 lb. ft) and angle-tighten 90° . Use bevel protractor 9512050 .

Tighten the lower engine pad screw to 50 Nm (36.9 lb. ft) .

Install splashguard under engine.

Install the left front wheel according to Installing wheels .

Lower the car.

Install

1. a new nut in the engine pad upper mounting. Tighten to 50 Nm (36.9 lb. ft) .
2. the intake manifold between air cleaner (ACL) and the electronic throttle module (ETM). Applies only to B6xx4S .
3. the cross stay between the suspension turrets. Tighten the four screws to 50 Nm (36.9 lb. ft) .
4. a new screw for the torque rod mounting at the bracket on the engine. Tighten to 80 Nm (59.0 lb. ft) .

Replacing Rear Engine Pad

Special tools

9995972

9512050

Remove

1. the torque rod mounting screw at the bracket on the engine.
2. screws at cross rod mounting to suspension turret.
3. cross member.
4. the rear engine pad upper nut.

Raise car and remove

1. left front wheel.
2. the splash guard under the engine.
3. the screw at the lower torque rod mounting for the bracket on the transmission.
4. the engine pad lower screw.

1. the screws at the front cross member (x4).
2. the exhaust pipe mounting screws in the front cross member.
3. brake pipe from its holder in the member.

1. the exhaust flange nuts and gaskets.

1. the nuts at the rear cross member holding the exhaust pipe to the member.

Lift the three-way catalytic converter (TWC) and exhaust pipe backwards

Lift up the exhaust pipe mounting from the rear member. Use a jimmy bar. Pull the exhaust pipe backwards so that the mounting ends up behind the member.

Move the three-way catalytic converter (TWC) and exhaust system backward.

Remove the screws for the sub-frame bracket holding the heated oxygen sensor (HO2S) cable.

Position a mobile jack with universal plate 9995972 under oil pan long, as far to the left as possible.

Note. Dry off the oil pan and the universal plate.

Check that the plate does not catch in the sub-frame.

Carefully lift up the engine so that the engine pad can be replaced.

Install a new screw in the engine pad lower mounting. Do not tighten yet.

Carefully lower the engine.

Note. Ensure that engine pad locating pin locates correctly.

Remove the mobile jack.

Lift up the exhaust pipe at the rear member. Move the exhaust system forwards.

Install

1. the rubber mounting in the cross member.
2. the nuts on the rear mounting. Tighten to 25 Nm (18.4 lb. ft) .

1. the three-way catalytic converter (TWC) and exhaust pipe on the engine. Use new nuts and gaskets .
2. exhaust manifold nuts. Tighten to 25 Nm (18.4 lb. ft) .

1. the screws for the bracket.
2. the connectors in the sub-frame.

1. exhaust pipe mounting screws. Tighten to 10 Nm (7.4 lb. ft) .
2. the brake pipe in its holders.
3. the cross member screws. Tighten to 25 Nm (18.4 lb. ft) .

Install a new screw in the lower torque rod. Tighten to 35 Nm (25.8 lb. ft) and angle-tighten 90° . Use bevel protractor 9512050 .

Tighten the lower engine pad screw to 50 Nm (36.9 lb. ft) .

Install splashguard under engine.

Install the left front wheel according to Installing wheels .

Lower the car.

Install

1. a new nut in the engine pad upper mounting. Tighten to 50 Nm (36.9 lb. ft) .
2. the cross stay between the suspension turrets. Tighten the four screws to 50 Nm (36.9 lb. ft) .
3. a new screw for the torque rod mounting at the bracket on the engine. Tighten to 80 Nm (59.0 lb. ft) .

Replacing Right Engine Pad

Special tools

9995972

9512050

Removing Right Engine Pad

Raise the car.

Remove

1. right front wheel.
2. both plastic nuts and reinforcement panel holding cover in right fender liner. Bend fender liner out of the way.
3. the crankshaft vibration damper.
4. four screws for right engine pad.

Scheme 258

Position a mobile jack with universal plate 9995972 under oil pan on right-hand side of engine.

Check that the plate does not catch in the sub-frame.

Carefully lift engine slightly so that the engine pad can be removed.

Scheme 259

Install

1. the new engine pad.
2. new screws for the mounting in the sub-frame (A) and engine (B). Do not tighten yet.

Carefully lower the engine and remove mobile jack.

Tighten the screws to the sub-frame to 65 Nm (47.9 lb. ft) and angle-tighten 60° . Use bevel protractor 9512050 .

Tighten the screws to the engine to 35 Nm (25.8 lb. ft) and angle-tighten 90° .

1. the crankshaft vibration damper. Tighten to 35 Nm (25.8 lb. ft) . Angle-tighten 50° .
2. both the plastic nuts holding the cover in the right fender liner.
3. right front wheel according to «Installing wheels»(ref-461711-S34187254862012040200000) .

Replacing The Front Sub-Frame

Special tools

See 9995716

See 9995460

See 9995045

See 9512050

(6 cylinder engines only) Installing the lifting tools. See Lifting Tools Removing/Installing For 6 Cylinder Cars .

1. Install lifting beam «9995716»(ref-403953-S41765249862011061000000) . Install lifting hooks «9995460»(ref-403953-S32932431362011061000000)
2. Lift the engine to relieve the load on the engine pads.

Remove

1. the front wheels
2. the splash guard under the engine.

Scheme 260

1. the air duct cover.

1. the cable duct screw.

Remove

1. the oil pipes from the steering gear from the snap fasteners on the sub-frame
2. the hose for the EVAP canister
3. the fuel line for the engine block heater and the engine block heater (if applicable) on the left side of the sub-frame.

Scheme 261

1. the hose for the EVAP canister in the joint by pulling apart the hose. Route the hose under the anti-roll bar.

Scheme 262

Remove

1. the mounting for the exhaust pipe on the bracket
2. the screws holding the exhaust pipe bracket. Disconnect the brake pipe from the snap fasteners on the bracket
3. the bracket.

Scheme 263

1. Remove the cable harness from the rear edge of the sub-frame. Disconnect the connectors. (Applies only to cars with 6-cylinder engines)
2. Remove the heated oxygen sensor (HO2S) bracket from the mounting.

Scheme 264

1. Remove the anti-roll bar links from the anti-roll bar. Counterhold with a Torx wrench so that the ball joint boot is not damaged.

1. Remove both the nuts retaining the lower torque rod
2. Remove the screw and bend up the bushing with the holder towards the torque rod.

1. Remove the front engine pad screw.

1. Slacken off the right lower front part of the fender liner.
2. Remove the plastic nuts on the fender liner
3. Remove the splash guard
4. Bend out the fender liner.

Remove the four vibration damper screws. Counterhold the crankshaft central nut.

Remove

1. the vibration damper (applies to 6-cylinder cars).

Scheme 265

1. Remove both the right hand engine mounting screws.

1. Remove the four nuts and the screw holding the steering gear to the sub-frame
2. Remove the delivery line from the clips on the sub-frame

Scheme 266

1. Remove the nuts from the ball joints. Counterhold with a Torx wrench so that the ball joint boot is not damaged.

Scheme 267

1. Position a lifting table under the sub-frame
2. Remove the screws holding the sub-frame brackets to the bodywork on both sides
3. Remove the four screws from the sub-frame
4. Carefully lower the sub-frame. NOTE: Ensure that the steering gear screws are released from the sub-frame.

Scheme 268

Hang the steering gear from a hook 9995045 so that the lower steering shaft does not come apart.

Scheme 269

Transfer

1. the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) . Tighten the rear screw. Tighten to 105 Nm . Angle-tighten 90°
2. the anti-roll bar. Tighten to 60 Nm
3. the right-hand engine mounting. Tighten the screws. Tighten to 65 Nm . Angle-tighten 60°
4. the mounting for the heated oxygen sensor (HO2S) wiring
5. the engine pad.

Install new pipe / hose holders.

Installing The Sub-Frame

1. Position the sub-frame on a lifting table
2. Carefully lift the sub-frame
3. Locate the control arms on the ball joints and the steering gear on its mountings
4. Remove the hook (999 5045) that is holding the steering gear
5. Lift the sub-frame up completely.

1. Install the four screws in the subframe together with the sub-frame brackets. Use new screws . Lubricate the screws
2. First tighten the screws on the left-hand side of the sub-frame. Tighten to 105 Nm . Angle-tighten 120° . Then tighten the right-hand side to the same values
3. Finally tighten the screws for the brackets on both sides to 50 Nm .

Install

1. the right-hand engine mounting. Use new screws Tighten to 35 Nm . Angle-tighten 90° .

Scheme 270

1. the vibration damper. Use new screws. Tighten to 35 Nm . Angle-tighten 90° . (Applies to cars with 6 cylinder engines.).

1. the front engine pad. Tighten to 50 Nm .

1. lower torque rod. Tighten to 35 Nm . Angle-tighten 90° . The lower torque rod must be tightened last to avoid tension being introduced. Tighten the nuts. Tighten to 65 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) . NOTE: Use new screws and new nuts.

1. the fender liner and the splash guard with both the plastic nuts.

1. the four nuts and screws holding the steering gear. Use new nuts and new screws. Tighten to 50 Nm Clip the cable in position.

1. the cable harness at the rear edge of the sub-frame and connect the connectors. (Applies only to cars with 6-cylinder engines)
2. the heated oxygen sensor (HO2S) bracket in its mounting.

1. the mounting for the exhaust pipe on the bracket. Tighten to 10 Nm
2. the brake pipe on the exhaust pipe bracket
3. the exhaust pipe bracket. Tighten the bracket screws. Tighten to 25 Nm .

1. EVAP canister hose. Press the joint together.

1. the oil pipe to the steering gear
2. the hose for the EVAP canister
3. any fuel line for engine block heater
4. any engine block heater.

1. new nuts on the ball joints. Tighten to 80 Nm . Counterhold with a Torx wrench so that the ball joint boot is not damaged.

1. the anti-roll bar links. Use new nuts. Tighten to 50 Nm . Counterhold with a Torx wrench so that the boot is not damaged.

1. the cable duct screw.

1. the air duct cover.

Scheme 271

1. the splash guard under the engine. Tighten to 20 Nm .

1. Install the wheels according to «Installing wheels»(ref-440302-S30067264572011121400000) . Lower the car
2. Remove the lifting tools. See «Removing Lifting Tools»(ref-440293-S34379915312011121400000) (applies to 6-cylinder engines)

Installing Lifting Tools

Installing lifting tools

Scheme 272

1. Install lifting beam «9995716»(ref-403953-S41765249862011061000000) . Install lifting hooks «9995460»(ref-403953-S32932431362011061000000)
2. Lift the engine to relieve the load on the engine pads.

Removing the charge air pipe and hose (6-cylinder turbocharged engines only)

Slacken off the 5 hose clamps for all the charge air pipes.

Remove the 2 screws from the charge air pipe on the intake manifold.

Separate all the charge air pipe. Leave the pipes lying on the spark plug cover.

Removing the spark plug cover

Remove

1. the screws for the spark plug cover
2. the cover
3. the ground strip screw.

Applies only to turbocharged engines

Remove the screws.

Lift up the delivery lines. Remove the spark plug cover.

Installing the lifting lug

Remove the 2 screws at the engine mounting.

Install lifting lug 9995717 .

Removing Lifting Tools

Remove the lifting lug and the lifting hook from the engine and the car

Remove the lifting lug from the engine. Install the screws. Tighten to 50 Nm .

Reinstall the spark plug cover. Tighten the screw. Tighten to 10 Nm .

Install the ground strip. Tighten to 10 Nm .

Lift up the delivery lines. Install the spark plug cover (applies only to turbocharged cars).

Installing the charge air pipe (only applies to 6 cylinder turbocharged engines)

Connect all the charge air pipes to each other.

Tighten the hose clamps.

Install the screws for the charge air pipe in the intake manifold. Tighten to 10 Nm .

See Replacing front engine pad

See Replacing rear engine pad

See Replacing right engine pad

See Replacing the front sub-frame

See Replacing front engine pad

See Replacing rear engine pad

See Replacing right engine pad

See Replacing the front sub-frame

See Replacing front engine pad

See Replacing rear engine pad

See Replacing right engine pad

See Replacing the front sub-frame

See Auxiliaries belt / belt tensioner, replacing

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

See Removing/Installing the rear camshaft seal .

Remove the timing belt from the timing gear pulley for the camshafts. See Replacing the timing belt .

Check the tensioner and idler pulleys. See Replacing the timing belt .

Remove camshaft position (CMP) sensor housing and the trigger wheel.

Remove the cover at the rear edge of the camshaft.

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one. Remove the plug from the front edge of the variable valve timing unit (Tx55).

Remove the center screw from the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing

Remove the screws. Remove the timing gear pulley.

Carefully press in tool 9995651 between the seal and the camshaft. Pry out the seal.

Note. The purpose of the "Installing the VVT unit/timing gear pulley" section described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Note. For tightening torques, see Tightening torque .

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. For camshafts with variable valve timing

Use drift 9995718 .

Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out. for camshafts without variable valve timing

Use drift 9995719 .

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Install

1. the starter motor. Tighten screws at gearbox. Tighten. See «Tightening torque»(ref-440295-S16446937762011121400000)
2. the screw at the support bracket for the starter motor. Tighten
3. the trigger wheel. Tighten the screw
4. the camshaft position (CMP) sensor housing. Tighten the screws
5. a new cover at the rear edge of the camshaft.

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the plastic nuts for the cover in the right-hand wing liner
2. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Install

1. front timing cover. Tension the auxiliaries belt. Check that it is correctly positioned on all pulleys
2. the expansion tank
3. the hose between the expansion tank and the radiator. Remove the lock grip pliers
4. the servo reservoir
5. the upper timing cover.

Install

1. the engine stabilizer brace. Tighten the screws
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten
3. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Check and top up if required

1. coolant level
2. the servo fluid level.

Test drive the engine.

Remove

1. the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
2. the air cleaner (ACL) cover. Place it to one side
3. the camshaft position (CMP) sensor housing and the trigger wheel.

Pull out the seal. Use puller 9995919 . To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 9995450 .

Note. The seal is normally positioned at the same level as the internally bevelled edge. If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm : Turn the drift socket.

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the air cleaner (ACL) cover
4. the intake manifold between the electronic throttle module and the air cleaner (ACL) cover.

Test drive the engine.

See Replacing the timing belt

See Variable valve timing solenoid, replacing

See Auxiliaries belt / belt tensioner, replacing

Camshaft Seal / Variable Valve Timing (VVT) Unit, Replacing

Special tools

9995452

9995651

9995718

9995719

9995451

9995919

9995450

9995750

Note. As 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.

See Removing/Installing the rear camshaft seal .

1. Remove the timing belt from the timing gear pulley for the camshafts. See «Replacing the timing belt»(ref-440293-S07193705732011121400000) .
2. Check the tensioner and idler pulleys. See «Replacing the timing belt»(ref-440293-S07193705732011121400000) .
3. Remove the camshaft position (CMP) sensor housing and the trigger wheel
4. Remove the cover at the rear edge of the camshaft.

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one.

Remove the plug from the front edge of the variable valve timing unit (Tx55). Remove the center screw from the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing

Remove the screws and the timing gear pulley.

Carefully press in tool 9995651 between the seal and the camshaft. Pry out the seal.

Note. The purpose of the section, "Installing the variable valve timing unit/timing gear pulley", described here is to ensure that the variable valve timing unit is correctly positioned but also to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Note. For tightening torques, see: Tightening torque .

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal.

For camshafts with variable valve timing: Use drift 9995718 .

Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out.

For camshafts without variable valve timing: Use drift 9995719 .

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Install

1. the starter motor. Tighten screws at gearbox. Tighten. See «Tightening torque»(ref-440295-S16446937762011121400000) .
2. the screw at the support bracket for the starter motor. Tighten
3. the trigger wheel. Tighten the screw
4. the camshaft position (CMP) sensor housing. Tighten the screws
5. a new cover at the rear edge of the camshaft.

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the plastic nuts for the cover in the right-hand wing liner
2. the right front wheel. See «Installing wheels»(ref-440302-S30067264572011121400000) .

Install

1. front timing cover. Tension the auxiliaries belt. Check that it is correctly positioned on all pulleys
2. the expansion tank
3. the hose between the expansion tank and the radiator. Remove the lock grip pliers
4. the servo reservoir
5. the upper timing cover.

1. the engine stabilizer brace. Tighten the screws
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten
3. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Check and top up if required

1. coolant level
2. the servo fluid level.

Test drive the engine.

Remove

1. the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
2. the air cleaner (ACL) cover. Place it to one side
3. the camshaft position (CMP) sensor housing and the trigger wheel.

Pull out the seal. Use puller 9995919 .

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 9995450 .

Note. The seal is normally positioned at the same level as the internally bevelled edge. If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm : Turn the drift socket.

For tightening torques, see: Tightening torque .

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the air cleaner (ACL) cover
4. the intake manifold between the electronic throttle module and the air cleaner (ACL) cover.

Final check

Test drive the engine.

See Replacing the timing belt

See Variable valve timing solenoid, replacing

Engine/Transmission, Installing

Special tools

9512050

9995972

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Note. For tightening torques, see Tightening torque

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Scheme 273

Raise the engine and the transmission unit. Use a lifting table with locating pins.

Stop when the sub-frame is approximately 15 cm below the frame members.

Scheme 274

Install (left and right-hand sides)

1. the drive shaft to the hub. Install the center screws. Do not tighten yet.
2. the ball joint to the control arm. Install the nuts. Do not tighten yet. NOTE: Ensure that the mating surfaces on the ball joints and control arms are clean.

Twist the engine block heater (option) into position. Check that the air conditioning (A/C) compressor is correctly positioned.

Check that the tie rod is in the correct position. Check that the transmission cable is routed between the steering shaft and the firewall.

Align the steering shaft joint on the steering gear.

Lift the engine and transmission unit up to the frame members.

Note. Ensure that no hoses, wiring or anything else catches.

Install

1. a new screw in the lower steering shaft joint. Tighten to 20 Nm
2. new screw in the sub-frame. Lubricate the screws
3. the washes at the front edge and the support plates at the rear edge of the sub-frame.

Tighten the screws for the sub-frame. Tighten to 105 Nm . Angle-tighten 120° . Use bevel protractor 9512050 . Start on the left hand side of the sub-frame. Continue with the right hand side.

Tighten the screws for the brackets at the rear of the sub-frame. Tighten to 50 Nm .

Remove the lifting table.

Installing The Propeller Shaft (All-Wheel Drive (AWD) Only)

Install the propeller shaft (all-wheel drive (AWD) only). See Propeller shaft - removal, replacement and installation .

Installing The Three-Way Catalytic Converter (TWC) (All-Wheel Drive (AWD) Only)

Lubricate the studs where the exhaust system separates downstream of the three-way catalytic converter (TWC). Use paste 116 1408.

Lift up the exhaust system and connect it to the rear system. Use a new gasket and new nuts.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Note. The routing of the heated oxygen sensor (HO2S) wiring over the brake pipe.

Install the screws holding the SIPS member to the bodywork. Tighten the screws.

Press the brake pipe into place in the holders on the SIPS member.

Installing The Front Exhaust Pipe

Lubricate the studs on the turbocharger (TC). Use paste 116 1408.

Install the front exhaust pipe on the turbocharger (TC). Use new nuts. Tighten to 30 Nm .

Clamp the wiring for the rear heated oxygen sensor (HO2S) into place at

1. the bracket at the rear of the sub-frame
2. the clips on the power steering pipe at the steering gear
3. the clamp at the right-hand side of the steering gear.

Scheme 275

When assembling the fuel lines, see also: Fuel system, quick-release connectors .

Connect the quick-release connector and the fuel line to

1. the motor
2. the engine block heater (option).

Press the EVAP line together at the rubber joint.

Scheme 276

Install

1. the tie rods. Use new nuts. Tighten to 70 Nm
2. the link rod to the anti-roll bar. Use new nuts. Tighten to 50 Nm . Counterhold with Tx27
3. the bracket for the brake pipe to the body.

Tighten

1. the nut for the ball joint and control arm. Tighten to 80 Nm . Counterhold using Tx40
2. the center screw in the drive shaft. Tighten to 50 Nm .

Scheme 277

Connect the heater connector at the vehicle wiring.

Ensure that the connector and wiring are secured at the body.

Rivet the fender liner to the fender edge.

Check that the quick-release fuel line connector is secure at the engine block heater.

Scheme 278

Install the 4 screws whilst the compressor is loose.

Raise the compressor and screw it into place.

Note. Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) pipes.

Connect the one-pin connector to the compressor magnetic clutch.

Scheme 279

Connect the engine wiring to the control module box. See Central electrical unit, engine compartment, replacing .

Install

1. the ground lead to the ground terminal at the right fender edge in the engine compartment
2. the auxiliaries belt
3. the intermediate piece for the control module box
4. the control modules. See «Engine control module (ECM), replacing»(ref-440263-S40872388582011121400000)
5. the cover for the control module box
6. expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
7. servo oil reservoir. Check that the hoses are correctly positioned.

Clamp the ABS cable to the power steering hose.

Scheme 280

Install

1. the heat deflector plate above the turbocharger (TC)
2. the 2 ground strips on the top of the cylinder head.

Clamp the wiring for the front heated oxygen sensor (HO2S) to

1. the coolant pipe
2. the heat deflector plate above the manifold
3. the turbo control hose at the plastic intake pipe for the turbocharger (TC).

Scheme 281

Install

1. the positive lead for the starter motor
2. the connector for the engine wiring
3. the cover over the central electrical unit.

Installing The Transmission Cable

Install the screws holding the bracket and transmission cable to the transmission.

Scheme 282

Install

1. the lower engine coolant hose to the radiator. Tighten the clamp
2. the lower oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings
3. the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Only connect the plastic pipe at the throttle body (TB). Do not tighten the clamp.

Remove radiator protection 999 5474

Install

1. the engine cooling fan (FC). Tighten the screws securing the fan shroud to the front panel
2. the plastic charge air pipe to the connection at the charge air cooler (CAC). Tighten both the clamps. Connect the connectors for the temperature and pressure sensors in the plastic pipe
3. the canister purge (CP) valve to the bracket at the fan shroud. Secure the EVAP hose to the clip at the lower section of the fan shroud
4. the brake vacuum hoses
5. the upper oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings.

Scheme 283

Press down the right side of the cooler unit. Pull the wiring for the pressure switch (Pressostat) into the drier bottle.

Connect the connectors to

1. the engine cooling fan (FC) (x2)
2. the canister purge (CP) valve.

Secure

1. the breather tube for the radiator at the top of the fan shroud
2. the wiring at the lower right corner and at the top of the fan shroud.

Install

1. the rubber hose to the inlet side of the charge air cooler (CAC)
2. the plastic charge air pipe above the engine. Tighten all clamps. Secure the pipe on the engine
3. the upper coolant hose. Tighten the clamp
4. the ventilation pipe between the control module box and fan shroud
5. the air cleaner (ACL) assembly. Connect the plastic hose to the mass air flow (MAF) sensor. Tighten the clamp
6. the air cleaner (ACL) intake pipe.

Connect the connector to the mass air flow (MAF) sensor. Secure the wiring at the front of the air cleaner (ACL) housing.

Install the support brace between the suspension turrets. Secure the servo hose to the right mounting on the support brace.

Scheme 284

Connect the connector to the pressure switch (Pressostat) in the drier bottle. Secure the wiring.

Tighten the lower screw on the cooler unit.

Connect the connectors to both the heated oxygen sensors (HO2S).

Scheme 285

Install

1. the splash guard under the radiator
2. the splash guard under the engine
3. the front wheels. See «Installing wheels»(ref-461711-S34187254862012040200000)
4. the battery negative lead. Also read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Top up

1. coolant
2. engine oil
3. power steering fluid.

Start the engine.

Warm up the engine until the thermostat opens.

Check for leakage.

Check the oil and coolant levels. Adjust if necessary.

Check the transmission oil level (automatic transmissions only). Top up if necessary.

Lifting The Engine And Transmission To The Horizontal Position

Raise the vehicle

Scheme 286