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| The engine must be no more than warm to touch. |
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| The pistons must not be positioned at TDC. |
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| First check whether a coded radio is fitted. If so, obtain anti-theft coding. |
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| With the ignition switched off, disconnect battery earth strap. |
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| First remove main drive toothed belt → Chapter. |
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| Remove roller rocker fingers together with support elements and lay aside on clean surface. |
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| Ensure that roller rocker fingers and support elements are not interchanged. |
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| Open and close expansion tank cap to release pressure in cooling system. |
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| Loosen hose clips and pull coolant hoses off coolant thermostat housing. |
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| Remove oil dipstick tube. |
WARNING | Fuel supply lines are under pressure! Wear protective glasses and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. |
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| Pull fuel supply line off fuel rail. |
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| Seal lines so that fuel system is not contaminated by dirt. |
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| Loosen or separate the following components: |
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| hose from active charcoal filter to intake manifold |
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| vacuum hose from brake servo to intake manifold |
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| 2-pin connector from knock sensor (back of cylinder block) as well as 4-pin connector from intake manifold pressure sender with intake air temperature sender |
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| the connector from engine speed sensor, located below oil dipstick guide tube bracket |
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| the connector from coolant temperature sender, oil pressure switch and exhaust gas recirculation valve |
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| the throttle valve control module connector |
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| the injectors connectors |
| Engine codes BBY, BBZ, BKY |
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| the connector from heated vacuum valve on oil separator |
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| the hose from crankcase breather |
| Continuation for all vehicles |
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| Pull off or disconnect all other electrical connections as necessary from engine and lay clear. |
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| Remove fuel rail complete with all injectors → Chapter. |
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| Remove thermostat housing from cylinder head. |
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| Remove front exhaust pipe from exhaust manifold. |
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| Remove rear toothed belt guard securing bolt (near right-hand lifting eye). |
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Note
