Removing both cylinder heads

Preliminary work

Refer to REMOVING THE COMPLETE FRONT AXLE WITH THE ENGINE AND TRANSMISSION .
Refer to REMOVING THE RIGHT THROTTLE BODY .
Refer to PARTIALLY LOOSENING THE RIGHT-HAND CHARGE AIR COOLER .
Refer to PARTIALLY LOOSENING THE LEFT-HAND CHARGE AIR COOLER .
Refer to REMOVING THE ENGINE VENTILATION LINE FROM THE INTAKE SYSTEM .
Refer to REMOVING THE TANK VENT LINE .
Refer to REMOVING THE INTAKE PLENUM .
Refer to REMOVING TOP RIGHT CLEAN AIR PIPE .
Refer to REMOVING TOP RIGHT CLEAN AIR PIPE .
Refer to REMOVING RIGHT CHARGE AIR PIPE .
Refer to REMOVING THE LEFT-HAND VENTILATION LINE .
Refer to REMOVING THE RIGHT-HAND VENTILATION LINE .
Refer to REMOVING IGNITION COILS .
Refer to REMOVING LEFT HIGH PRESSURE LINE BETWEEN HIGH PRESSURE PUMP AND RAIL .
Refer to REMOVING THE RIGHT HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
Refer to REMOVING ALL HIGH PRESSURE LINES BETWEEN RAIL AND INJECTORS .
Refer to REMOVING THE HIGH-PRESSURE RAIL ON THE LEFT .
Refer to REMOVING RIGHT RAIL .
Refer to REMOVING LEFT HIGH PRESSURE PUMP .
Refer to REMOVING RIGHT HIGH-PRESSURE PUMP .
Refer to REMOVING INJECTORS .
Refer to PARTIALLY RELEASING THE WIRING HARNESS FROM RIGHT CYLINDER HEAD COVER .
Refer to PARTIALLY RELEASING THE WIRING HARNESS FROM THE CYLINDER HEAD COVER ON THE LEFT .
Refer to RELEASING THE OIL DRAIN PLUG .
Refer to TIGHTENING THE OIL DRAIN PLUG .
Refer to REMOVING THE CATALYTIC CONVERTER FOR CYLINDERS 1 TO 6 .
Refer to REMOVING THE CATALYTIC CONVERTER FOR CYLINDERS 7 TO 12 .
Refer to RELEASING THE COOLANT LINE FOR THE TURBOCHARGER ON THE LEFT .
Refer to REMOVING LEFT CYLINDER HEAD COVER .
Refer to REMOVING BOTH SOLENOID VALVES ON LEFT SIDE .
Refer to REMOVING THE TOP TIMING CASE COVER OF CYLINDERS 7 TO 12 .
Refer to RELEASING COOLANT FEED LINE FOR THE RIGHT TURBOCHARGER .
Refer to REMOVING RIGHT CYLINDER HEAD COVER .
Refer to REMOVING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to REMOVING BOTH SOLENOID VALVES ON RIGHT SIDE .
Refer to REMOVING THE TOP TIMING CASE COVER FOR CYLINDERS 1 TO 6 .
Refer to REMOVING THE DRIVE BELT FOR ALTERNATOR 2 AND THE AIR CONDITIONING COMPRESSOR .
Refer to REMOVING THE DRIVE BELT FOR ALTERNATOR .
Refer to REMOVING THE BELT PULLEY .
Refer to REMOVING THE ALTERNATOR .
Refer to REMOVING RIGHT CLEAN AIR PIPE .
Refer to REMOVING AIR CONDITIONING COMPRESSOR .
Refer to REMOVING ALTERNATOR 2 .
Refer to REMOVING LEFT CLEAN AIR PIPE .

Place the 1st and 7th cylinder into the TDC setting

Position the special tool 0 496 366 (11 8 570) on the mark on the vibration absorber.
Attach the special tool 0 496 366 (11 8 570) with a screw (1) on the vibration absorber and hand-tighten.

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Cylinder bank 1 (cylinders 1 to 6)
Turn the engine in direction of rotation until the cams on the 1st cylinder point upward inwards .
Cylinder bank 2 (cylinders 7 to 12)
Turn the engine in direction of rotation until the cams on the 7th cylinder point upward outwards .
The narrow, processed surfaces (arrows) for securing the camshafts must point upwards.

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Make sure that labeling (A or E) (1) in the center of the camshafts is legible.

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Turn the engine in direction of rotation until the special tool 0 496 366 (11 8 570) can be fastened with the 0 493 882 (11 9 190) in the groove (arrow.

The crankshaft is fastened in the TDC setting of the cylinder.

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Remove the special tools to disconnect the crankshaft

Remove the special tool 0 493 882 (11 9 190) and the special tool 0 496 366 (11 8 570) .

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Release the chain tensioner

NOTE: RISK OF DAMAGE
Damage to timing chain or timing chain drive.
Turning the engine without chain tensioner or special tool can result in damage to the timing chain and timing chain drive.

Always turn the engine with the chain tensioner or the special tool.

Turn the engine back in the opposite direction by 90° at the central bolt (1) (see graphic).
The piston (1) of the chain tensioner must be pressed against the oil pressure in the housing (see arrow).
Graphic N63.

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Remove the hydraulic chain tensioner

NOTE: RISK OF DAMAGE
Damage to timing chain or timing chain drive.
Turning the engine without chain tensioner or special tool can result in damage to the timing chain and timing chain drive.

Always turn the engine with the chain tensioner or the special tool.

Fasten the chain tensioner piston above the bore with the special tool 0 491 012 (11 4 120) .
Loosen screws (1).
Remove the hydraulic chain tensioner (2).

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Installing special tool to pre-tension timing chain

NOTE: RISK OF DAMAGE
Damage to timing chain or timing chain drive.
Turning the engine without chain tensioner or special tool can result in damage to the timing chain and timing chain drive.

Always turn the engine with the chain tensioner or the special tool.

Screw special tool 0 496 360 (11 9 900) in on the cylinder head by hand.
Pretension timing chain with special tool 0 496 360 (11 9 900) to 0.6 Nm.

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Check timing

NOTE: RISK OF DAMAGE
Damage of the engine and installed parts.
Non-compliance with the instructions for mounting and disassembly may lead to damage to the engine and installed parts.

Comply with the regulations for the installation and disassembly.
Perform work with vehicle care.

Check the lock of intake and exhaust camshaft adjusters.
Position open-end spanner (1) on the hexagon head of the camshaft (2).
Move open-end spanner slightly back and forward in direction of arrow.
The camshafts must have a positive-type connection to the VANOS adjusters.
If no power transmission exists, the affected adjuster must be replaced.

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Insert special tool 0 496 366 (11 8 570) .
Slowly turn engine until the special tool 0 493 882 (11 9 190) can be slid into the groove on the crankcase.

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NOTE:
RISK OF DAMAGE
Damage to the engine.
If the engine is manually rotated in the wrong direction of rotation, the engine can be damaged.
- Only rotate the engine manually in the correct direction of rotation: a) clockwise when looking at the damper, or b) counterclockwise when looking at the chain drive. b) applies only if the timing chain is installed in the rear.
Rotate engine 2 turns in direction of rotation at the crankshaft.

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Incorrect assembly of the special tool is possible.
Make sure that labeling (A or E) (1) in the center of the camshafts is legible.

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Check
Place the special tools 0 496 381 (11 9 893) flush onto the surface on the cylinder head.
Determine the air gap with a feeler gage.
NOTE: TECHNICAL INFORMATION
If the check finds that the valve timings are incorrect, they must be adjusted.
For additional information, see: ADJUSTING CAMSHAFT TIMING ON LEFT SIDE , and ADJUSTING CAMSHAFT TIMING ON RIGHT SIDE .
A maximum measured value of 0.4 mm is permitted at the intake and exhaust camshaft to the intake side.

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Result

» Air gap greater than 0.4 mm.

Measure
- Adjust valve timing.
Remove special tools 0 496 381 (11 9 893) .

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Installing special tool for fastening camshafts

NOTE: RISK OF DAMAGE
Damage of the engine and installed parts.
Non-compliance with the instructions for mounting and disassembly may lead to damage to the engine and installed parts.

Comply with the regulations for the installation and disassembly.
Perform work with vehicle care.

Incorrect assembly of the special tool is possible.
Make sure that labeling (A or E) (1) in the center of the camshafts is legible.

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Place the special tools 0 496 381 (11 9 893) out of the set of special tools 0 496 359 (11 9 890) flush onto the surface on the cylinder head.
Determine the air gap with a feeler gauge.
The value measured for the air gap on the intake camshaft and the exhaust camshaft must not be more than 0.4 mm.

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Screw in special tools 11 9 895 1 to 6 and 7 to 12
Screw the special tools 0 496 359 (11 9 890) into the cylinder head at 10 Nm.

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Fastening the camshafts with the special tool

Position the special tool 0 496 380 (11 9 892) on the special tool (gauges) 0 496 381 (11 9 893) .
Apply the special tool 0 496 379 (11 9 891) hand-tight.

The gauges 0 496 381 (11 9 893) must rest flush on the cylinder head.

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Remove the upper slide rail

NOTE: The figure shows cylinders 1 to 6.

Loosen screws (1) and (2).
Remove the slide rail (3).

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Loosening both central bolts of VANOS gear

Unscrew the central bolts (1) of the exhaust and intake adjuster.

If the camshafts cannot be fastened with the special tool 0 496 381 (11 9 893) , the respective camshaft must be counter supported on the hexagon head with a opened spanner.

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Removing intake adjuster at cylinder 7 to 12

Remove the intake adjuster (1) from the camshaft.
(1) Remove the timing chain from the intake adjuster.
Place intake adjuster (1) neatly in special tool 0 495 105 (11 4 480) .

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Remove the exhaust camshaft adjuster for cylinders 7 to 12

Remove the VANOS exhaust camshaft adjuster (1) from the camshaft.
Remove the timing chain from the exhaust adjuster (1).
Place exhaust camshaft adjuster (1) neatly in special tool 0 495 105 (11 4 480) .

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Remove the special tools to fix the camshafts

Release special tool 0 496 379 (11 9 891) .
Remove special tool 0 496 380 (11 9 892) .

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Remove special tool 0 496 383 (11 9 895) .

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Remove special tools 0 496 381 (11 9 893) .

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Remove left cylinder head

Screw connection of the cylinder head

Fig 1: Left Cylinder Head Screws Loosening Sequence

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Release the wiring harness (1) from the clamps (arrows) and place aside.
Release the cable from the bracket at rear on the cylinder head.

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NOTE: Description is for right component only. The procedure on the left side is identical.
Release the positive battery cable (1) from the holders (2) and place it to one side.

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Release the bearing screw (1) of the guide rail.

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Release spring strap clamps (1).
Pull off the coolant hoses.

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Loosen screws (1).
Loosen screws (2).
Feed out and remove the heat shield.

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Release the screw connection of the heat shield (1) on the engine support bracket.
Feed out and remove the heat shield (1).

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Unlock the connector (1) of the wastegate valve controller and remove.

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Unlock connector (1) of the blow-off valve and remove.

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Release the screw of the oil return line on the turbocharger from the bottom with a long extension.
Release the oil return line (1) from the turbocharger.

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Unscrew the screw (1) and remove the coolant feed line.

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Release the spring strap clamp (2).
Detach the coolant return line.

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Unscrew the screw (1) from the ground cable.

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Install the special tool 0 493 997 (11 8 350) with the screws (M6x25) on the rear cylinder head.

Tighten the screws.

TIGHTENING TORQUE SPECIFICATIONS

Standard screw connection M6
M6	Tightening torque	8 Nm

Install the special tool 0 493 987 (11 8 260) with the screws (M6x25) on the front cylinder head.

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Tighten the screws.

TIGHTENING TORQUE SPECIFICATIONS

Standard screw connection M6
M6	Tightening torque	8 Nm

Unscrew the bolts (1) on the cylinder head.

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Release the cylinder head bolts in the order (14) to (1).
Remove cylinder head bolts (14) to (1) with washers.

Fig 2: Left Cylinder Head Bolts Loosening Sequence
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Attach special tool 0 490 567 (11 0 020) to workshop crane.
Fasten the special tool 0 490 567 (11 0 020) on the special tools 0 493 997 (11 8 350) and 0 493 987 (11 8 260) .

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NOTE:
RISK OF DAMAGE
Heavy component.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
The cylinder head must be guided during the removal procedure.
Two support persons are required for removing the cylinder head.
Keep the timing chain (1) tensioned.

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NOTE:
RISK OF DAMAGE
Damage to guide rails.
The application of great force can damage the guide rails of the timing chain.
- When removing and installing the cylinder head, make sure that the cylinder head does not damage the guide rail.
Ensure that the guide rails of the timing chain are not damaged.
NOTE: TECHNICAL INFORMATION
Handle the timing chain carefully to protect the timing chain and timing chain drive from damage.
Carefully lift the cylinder head (2) with the special tool 0 490 567 (11 0 020) and a workshop crane.
Tilt the cylinder head (2) in the direction of the arrow.
Feed out the timing chain and the chain guide.
Remove the cylinder head (2) with the workshop crane toward the top front.

Installing special tool for fastening camshafts

NOTE: RISK OF DAMAGE
Damage of the engine and installed parts.
Non-compliance with the instructions for mounting and disassembly may lead to damage to the engine and installed parts.

Comply with the regulations for the installation and disassembly.
Perform work with vehicle care.

Incorrect assembly of the special tool is possible.
Make sure that labeling (A or E) (1) in the center of the camshafts is legible.

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Place the special tools 0 496 381 (11 9 893) out of the set of special tools 0 496 359 (11 9 890) flush onto the surface on the cylinder head.
Determine the air gap with a feeler gauge.

The value measured for the air gap on the intake camshaft and the exhaust camshaft must not be more than 0.4 mm.

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Screw in special tools 11 9 895 1 to 6 and 7 to 12

Screw the special tools 0 496 359 (11 9 890) into the cylinder head at 10 Nm.

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Fastening the camshafts with the special tool

Position the special tool 0 496 380 (11 9 892) on the special tool (gauges) 0 496 381 (11 9 893) .
Apply the special tool 0 496 379 (11 9 891) hand-tight.

The gauges 0 496 381 (11 9 893) must rest flush on the cylinder head.

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Remove the hydraulic chain tensioner

NOTE: RISK OF DAMAGE
Damage to timing chain or timing chain drive.
Turning the engine without chain tensioner or special tool can result in damage to the timing chain and timing chain drive.

Always turn the engine with the chain tensioner or the special tool.

Fasten the chain tensioner piston above the bore with the special tool 0 491 012 (11 4 120) .
Loosen screws (1).
Remove the hydraulic chain tensioner (2).

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Installing special tool for fastening camshafts

NOTE: RISK OF DAMAGE
Damage of the engine and installed parts.
Non-compliance with the instructions for mounting and disassembly may lead to damage to the engine and installed parts.

Comply with the regulations for the installation and disassembly.
Perform work with vehicle care.

Incorrect assembly of the special tool is possible.
Make sure that labeling (A or E) (1) in the center of the camshafts is legible.

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Place the special tools 0 496 381 (11 9 893) out of the set of special tools 0 496 359 (11 9 890) flush onto the surface on the cylinder head.
Determine the air gap with a feeler gauge.

The value measured for the air gap on the intake camshaft and the exhaust camshaft must not be more than 0.4 mm.

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Screw in special tools 11 9 895 1 to 6 and 7 to 12

Screw the special tools 0 496 359 (11 9 890) into the cylinder head at 10 Nm.

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Fastening the camshafts with the special tool

Position the special tool 0 496 380 (11 9 892) on the special tool (gauges) 0 496 381 (11 9 893) .
Apply the special tool 0 496 379 (11 9 891) hand-tight.

The gauges 0 496 381 (11 9 893) must rest flush on the cylinder head.

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Remove the upper slide rail

NOTE: The figure shows cylinders 1 to 6.

Loosen screws (1) and (2).
Remove the slide rail (3).

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Loosening both central bolts of VANOS gear

Unscrew the central bolts (1) of the exhaust and intake adjuster.

If the camshafts cannot be fastened with the special tool 0 496 381 (11 9 893) , the respective camshaft must be counter supported on the hexagon head with a opened spanner.

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Removing the exhaust camshaft adjuster for cylinder 1 to 6

Remove the VANOS exhaust camshaft adjuster (1) from the camshaft.
Remove the timing chain from the exhaust adjuster (1).
Place exhaust camshaft adjuster (1) neatly in special tool 0 495 105 (11 4 480) .

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Removing intake adjuster at cylinder 1 to 6

Remove the intake adjuster (1) from the camshaft.
(1) Remove the timing chain from the intake adjuster.
Place intake adjuster (1) neatly in special tool 0 495 105 (11 4 480) .

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Remove the special tools to fix the camshafts

Release special tool 0 496 379 (11 9 891) .
Remove special tool 0 496 380 (11 9 892) .

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Remove special tool 0 496 383 (11 9 895) .

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Remove special tools 0 496 381 (11 9 893) .

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Remove right cylinder head

Screw connection of the cylinder head

Fig 3: Right Cylinder Head Screws Loosening Sequence

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Unlock and disconnect the plug connection (1) to the wiring harness section for the sensor system of cylinders 7 to 12.
Release the wiring harness from the clamps (arrows) and place aside.
Release the cable from the bracket at rear on the cylinder head.

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Release the positive battery cable (1) from the holders (2) and place it to one side.

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Removing the coolant thermostat

Unlock and disconnect connector (1).
Unlock coolant hose (2) and detach.

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Loosen screw (1).

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Loosen screws (1).
Remove coolant thermostat.

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Release the bearing screw (1).

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Loosen screw (1).

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Release spring strap clamps (1).
Pull off the coolant hoses.

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Release the cable bracket (1) from the oil dipstick tube.
Release the screw (2) on the oil dipstick tube.

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Loosen screws (1).
Feed out and remove the heat shield.

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Release banjo bolt (1) of oil feed line.

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Unlock and disconnect the plug connection (1) of the wastegate valve controller.

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Unlock and disconnect the plug connection (1) of the blow-off valve.

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Unscrew screws (1) and (2) of the oil return line.
Remove oil return line.

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Unscrew screw (1) and remove the coolant return line.

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NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Unscrew screw (1) at the cylinder head (arrow).

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Unscrew the bolts (1) on the cylinder head.

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Release the cylinder head bolts in the sequence (14) to (1).
Remove cylinder head bolts (14) to (1) with washers.

Fig 4: Right Cylinder Head Screws Loosening Sequence
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Install the special tool 0 493 987 (11 8 260) at the front of the cylinder head using the screws (6x25).

Tighten the screws.

TIGHTENING TORQUE SPECIFICATIONS

Standard screw connection M6
M6	Tightening torque	8 Nm

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Attach the special tool 0 490 567 (11 0 020) to a workshop crane.
Fasten the special tool 0 490 567 (11 0 020) on the securing eye (1) and on the special tool 0 493 987 (11 8 260) .
NOTE:
RISK OF DAMAGE
Heavy component.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
NOTE: TECHNICAL INFORMATION
Perform this step carefully to prevent paint damage on the engine mount.

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The cylinder head (1) must be guided during the removal procedure.
Two support persons are required for removing the cylinder head.
Keep the timing chain tensioned.
NOTE:
RISK OF DAMAGE
Damage to guide rails.
The application of great force can damage the guide rails of the timing chain.
- When removing and installing the cylinder head, make sure that the cylinder head does not damage the guide rail.
Ensure that the guide rails of the timing chain are not damaged.
NOTE: TECHNICAL INFORMATION
Handle the timing chain carefully to protect the timing chain and timing chain drive from damage.
Carefully lift the cylinder head (1) in the arrow direction using the special tool 0 490 567 (11 0 020) and a workshop crane.
Guide out the timing chain and the chain guides.
Remove the cylinder head (1) forward and upward using the workshop crane.