Cylinder Head, Removing And Installing: Removing

• During installation, install all heat insulation sleeves at the same locations.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the upper front coolant pipes. Refer to UPPER FRONT COOLANT PIPES, REMOVING AND INSTALLING .

-- Remove the rear coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the left coolant pipes. Refer to LEFT COOLANT PIPES, REMOVING AND INSTALLING .

-- Remove the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Remove the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and remove the resonator -1-.

Fig 1: Identifying Resonator With Bolts

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Vehicles with SCR System: 

Fig 2: Identifying EGR Temperature Sensor

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-- Remove the connector -2- for the EGR Temperature Sensor -G98- from the bracket, disconnect it and free up the wire.

Vehicles with Parking Heater: 

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-- Lift the clamps -1 and 2-, loosen the hose clamps -3-, and remove the coolant hoses.

-- Remove the nuts -arrows- and the coolant pipes.

Continuation for All Vehicles: 

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-- Disconnect the connectors and free up the wires.

1. For the Exhaust Gas Temperature Sensor 4 -G648-
2. For the Exhaust Gas Temperature Sensor 3 -G495-
3. For the Exhaust Gas Temperature Sensor 2 -G448- (installed depending on the emissions standard)

-- Remove the connector -4- for the Heated Oxygen Sensor -G39- from the bracket, disconnect it and free up the wire.

AWD Vehicles: 

-- Remove the EGR cooler. Refer to EGR COOLER, REMOVING AND INSTALLING .

FWD Vehicles: 

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• Use the Hook Tool: T40207  to disconnect the connector -item 2- in the figure below . Disconnect the securing pin on the connector housing -1- -arrow-.

-- Loosen the hose clamp -1- and remove the air duct hose.

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-- Push the heat shield boot aside, disconnect the connector -2- and free up the wire.

Continuation for All Vehicles: 

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-- Loosen the double bolt -1-, push the coolant pipe slightly toward the rear.

-- Remove the bolts -2-, and push the emissions control module and on FWD vehicles the EGR cooler rearward.

-- Remove the bolt -2- and union nut -4-.

Fig 3: Identifying Bolts

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-- Remove the bolts -3 and 5- and the oil return pipe.

-- Remove the bolt -2- and only loosen the bolts -1, 3, and 4-.

Fig 4: Emissions Control Module Bracket - Tightening Sequence

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Vehicles with Camshaft Adjustment: 

Fig 5: Identifying Hose Clamp

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-- Disconnect the connectors -1 and 3-.

-- Loosen the hose clamp -2-.

Continuation for All Vehicles: 

Fig 6: Identifying Connectors

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-- Disconnect the connectors and free them up:

1 -  For the Charge Air Temperature Sensor after Charge Air Cooler -G811-

3 -  For the Charge Air Pressure Sensor -G31-

4 -  For the Charge Air Temperature Sensor In Front Of Charge Air Cooler -G810-

5 -  For the Throttle Valve Control Module -J338-

-- Remove the bolts -2 and 7- and remove the coolant hose -6-.

-- Place the left front coolant pipe aside.

-- Remove the bolt -1- for the oil dipstick tube.

Fig 7: Identifying Oil Dipstick Guide Tube Bolt

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-- Remove the bolts -2 and 3- for the intake manifold bracket.

Vehicles with Camshaft Adjustment: 

-- Remove the Throttle Valve Control Module -J338-. Refer to Throttle Valve Control Module -J338-, REMOVING AND INSTALLING .

Continuation for All Vehicles: 

Fig 8: Identifying Cover Bolt

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-- Disconnect the connector -3-.

-- Remove the bolt -1- and leave the cover -2- in the installation position.

-- Release the retainer -arrow- and remove the vacuum hose -1-.

Fig 9: Identifying Retainer

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-- Remove the vacuum hose -2-.

-- Remove the bolt -3-.

• Depending on the vehicle, there are different components.

-- Disconnect the connector -2- for the Engine Coolant Temperature Sensor - G62-.

Fig 10: Identifying Hose Clamp

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-- Loosen the hose clamp -1- and remove the coolant hose.

-- Remove the vacuum hose -3-.

-- Disconnect the connector for the glow plug. Refer to GLOW PLUG, REMOVING AND INSTALLING .

Fig 11: Identifying Pliers 3314 Positioned With Groove

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-- Move the wiring harness to the side.

-- Loosen the cylinder head bolts in the sequence -1 to 10-.

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• A second technician is needed to remove the cylinder head.

-- Move the cylinder head from the rear toothed belt guard toward the left and remove the tensioning roller at the same time.

-- Be careful not to damage the turbocharger oil return line.

-- Lay the cylinder head down being careful not to bend the oil return line. Place a piece of wood under the exhaust manifold if necessary.

• Do not lay the removed cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface.