Contents: For engines with the letter…⬇ For vehicles with the letter…⬇ For all cars ⬇ Installation ⬇
Remove the upper engine cover. Remove the air filter with the air intake sleeve. Remove the battery and battery holder. Remove the rear and lower boost air pipes. Disconnect the glow plug connector.
For engines with the letter designation BSW
Remove the front section of the exhaust pipe with the catalytic converter. Unscrew screws "1" and "2" and remove the turbocharger bracket. Disconnect the boost control system vacuum receiver intake hose. Unscrew the oil drain line on cylinder block "3". After unscrewing the oil supply line from the turbocharger and from the exhaust manifold, set them aside. Drain the coolant. Unscrew the inlet pipe from the inlet gas line and set it aside with the attached hoses. Using a hand vacuum pump and an air pressure vessel, drain the fuel from the return fuel hose of the tandem hay pump. Disconnect fuel hoses "1" and "4". Disconnect coolant hose "5".
Remove the central plug connector "2" for the pump-injector unit. Disconnect the plug connector "3" on the fuel temperature sensor "G81". Unscrew: the oil supply line from the oil filter holder, turbocharger, and from the fasteners.
After disconnecting coolant hose "1" from the tee, disconnect coolant hoses "2" and "3" from the connecting pipe. Disconnect plug connector "4" from the coolant temperature sensor.
Disconnect coolant hose "3" from fitting "4". Disconnect pump hose "6" from the dual pump.
For vehicles with the letter designation BLS
Important: Remove only the mounting bracket and disconnect the front section of the exhaust manifold with the particulate filter from the turbocharger.
Remove the front section of the exhaust pipe with the particulate filter. Remove the lower engine cover. Disconnect the plug connector on the EGR cooler changeover valve "N345" "arrow".
Disconnect the intake hose "2" near the vacuum receiver of the boost pressure control system. Disconnect the intake hose "3" near the pipe leading to the EGR bypass valve vacuum regulator. Disconnect the vacuum line on the tandem pump. Release the EGR cooler changeover valve "N345" from the holder.
Place the EGR cooler changeover valve "N345" with the connected intake hoses to the side. Disconnect the lubrication supply hose "1" from the turbocharger. Remove the lubrication supply pipe.
Disconnect the "arrow" intake rod from the brake booster.
Disconnect the coolant hose "arrow" from the coolant pipe.
After disconnecting the plug connector from the coolant temperature sensor "G62", release the electrical wire. Remove the connecting pipe leading to the EGR cooler. Remove screws "2" and hollow screw "3.".
Remove the turbocharger support with the oil drain line.
For all cars
Remove the liquid cooling system pump. After installing the "MP9-200 (10-222A)" suspension device with the lead screws inserted as shown in the figure, secure the engine with lead screw "B." Carefully lift the engine with lead screw "B." Remove the toothed drive belt.
Remove the drive gear and camshaft hub. Remove the timing belt tensioner roller. After unscrewing screw "3", remove the Hall sensor "G40" from the cylinder head. Unscrew screws "2" and "4".
Screw the "T10014" holder into the threaded hole on the water pump section of the cylinder block. Tightening torque: 20 Nm. Carefully grasp and lift the engine with lead screw "A" and thereby release lead screw "B". Remove lead screw "B". Remove the cylinder head cover.
After loosening the cylinder head mounting bolts in the specified sequence, unscrew them. After lifting the cylinder head, remove it to the side around the protective cover of the toothed drive belt.
Installation
Important: Cylinder head bolts must always be replaced. There must not be any oil or coolant in the blind holes for the cylinder head bolts. The new seal should only be removed from its packaging immediately prior to installation. The new gasket must be handled with extra care. Damage to the silicone layer and the knurled area leads to loss of sealing. Make sure that no contaminants enter the cylinders or the lubrication and coolant passages during cleaning of the cylinder head and block.
Carefully remove any remaining old gasket from the cylinder head and cylinder block using a chemical gasket remover. Before installing the cylinder head, rotate the crankshaft to the TDC mark. Rotate the crankshaft counterclockwise so that all pistons are at the same level before TDC. Check that both spring pins "1" for guiding the cylinder head are inserted into the cylinder block; if necessary, they should be inserted. Install a new cylinder head gasket. Inscription (spare part number) should be visible. After installing the cylinder head, install all cylinder head mounting bolts and tighten them by hand.
Tighten the cylinder head bolts in four stages in the sequence shown as follows.
| Step | Tightening |
| I | - Tighten with a torque wrench to a torque of 35 Nm. |
| II | - Tighten with a torque wrench to a torque of 60 Nm. |
| III | - Additional tightening - with a rigid wrench at 90° (1/4 turn). |
| IV | - Additional tightening - with a rigid wrench at 90° (1/4 turn). |
After securing the cylinder head and, accordingly, after securing the camshaft pulley, the camshaft should be turned so that the cams for the 1st cylinder point upwards. Before installing the timing belt, rotate the crankshaft to TDC in the direction of engine rotation. After installing the cylinder head, prime the tandem pump and cylinder head with fuel using a hand vacuum pump with a bleeder. Further installation is carried out in the reverse sequence of actions than removal. Count the fault memory and reset the memory contents. Check the oil level.