Removing the cylinder head

WARNING: Hot surfaces.
Risk of burning!

Perform all work only on components that have cooled down.

WARNING: Working on fuel system.
Risk of fire! Danger of explosion!

When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
No fire, sparks, open flames or smoking.

Preliminary work

Bring front compartment lid in the SERVICE POSITION .
Disconnect all battery GROUND LEADS .
Remove the rear left engine compartment COVER .
Remove the rear right engine compartment COVER .
Remove the hood rear SEAL .
Remove left and right WIPER ARM .
Remove the cowl COVER .
Remove the ACOUSTIC COVER .
Remove the left and right shock tower TENSION STRUT .
Remove the upper part FIREWALL .
Remove rear ACOUSTIC COVER .
Remove right sealing FRAME .
Remove the bottom second FIREWALL .
Remove the top right and left engine compartment COVER .
Remove left and right hood gasket STAND .
Remove the left and right FRONT-END STRUT .
Remove front CROSS CONNECTION .
Remove the rear top CROSS CONNECTION .
Remove all IGNITION COILS .
Remove all SPARK PLUGS .
Remove intake silencer HOUSING .
Remove the positive battery cable HOLDER .
Remove the lambda OXYGEN SENSOR .
Remove the oxygen SENSOR MONITOR .
Remove FUEL DELIVERY LINE .
Remove the HIGH PRESSURE LINE between the high pressure pump and the rail.
Remove the cylinders 1 to 3 RAIL with injectors.
Remove the cylinders 4 to 6 RAIL with injectors.
Remove HIGH PRESSURE PUMP .
Remove both ACTUATORS .
Remove the cylinder head COVER .
Remove the DME CONTROL UNIT .
Remove the integrated POWER SUPPLY MODULE (PDM).
Remove control unit BRACKET .
Remove the front UNDERBODY PROTECTION .
Remove the center UNDERBODY PROTECTION .
Remove rear UNDERBODY PROTECTION .
Remove the front right lower wheel arch COVER .
Remove the right steering assembly COVER .
Remove left and right tank COVER .
Remove the tunnel connect SUPPORT .
Remove EXHAUST SYSTEM .
Remove CATALYTIC CONVERTER .
Remove the exhaust turbocharger OIL RETURN LINE .
Drain the HIGH-TEMPERATURE COOLING SYSTEM COOLANT .
Drain the LOW-TEMPERATURE COOLING SYSTEM COOLANT .
Connect the high-temperature coolant radiator COOLANT LINE .
Connect the auxiliary coolant pump COOLANT LINE .
Remove the fan COWL .
Remove engine ventilation LINE .
Remove clean AIR PIPE .
Remove charge AIR LINE .
Remove the exhaust turbocharger heating element engine ventilation line ADAPTER .
Remove the COOLANT LINE between the coolant pump and cylinder head.
Remove tank VENT VALVE .
Remove the INTAKE PLENUM .
Block engine in TDC FIRING POSITION .
Remove CHAIN TENSIONER .
Release the intake adjuster VANOS CENTRAL VALVE .
Release the exhaust camshaft adjuster VANOS CENTRAL VALVE .
Remove the intake adjuster VANOS CENTRAL VALVE .
Remove the exhaust camshaft adjuster VANOS CENTRAL VALVE .
Remove intake ADJUSTER .
Remove exhaust camshaft ADJUSTER .
Remove the TEST GAUGES for securing the camshafts.

CAUTION: On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!

Wear suitable personal protective equipment.
Before performing any installation work, allow cooling system to cool down to less than 40°C.
Note warnings on cylinder head cover.

NOTE: RISK OF DAMAGE
Engine damage due to missing motor oil.
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train.

After replacing the cylinder head or the engine, do not start the engine without observing the repair notes.
It is imperative you observe the repair notes for cylinder head or engine replacement.
For ADDITIONAL INFORMATION , see: Repair notes for cylinder head or engine replacement

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

CAUTION: 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
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Prepare special tool 0 495 747 (11 8 580).

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Prepare special tool 0 490 567 (11 0 020).

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Prepare the special tool 2 220 718.

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Unlock plug connection (1) and disconnect.

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Unlock and loosen coolant line (1).
Catch and dispose of escaping coolant.
Unlock plug connection (2) and disconnect.
Loosen clamps (3).
Guide out the wiring harness section (4) for the sensor system (1) and set it aside.

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Unlock and detach the coolant return line (1) on the coolant pump (2) for the exhaust turbocharger.
Catch and dispose of escaping coolant.

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Loosen screws (1).
Loosen screw (2).
Feed out and remove the heat shield (3).

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

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Release the screw (1) at the coolant return line (2).

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Loosen screw (1).
Guide out the oil feed line (2) for the exhaust turbocharger and set it aside.
Catch and dispose of emerging engine oil.

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Loosen screws (1) and (2).
Guide the coolant feed line for the exhaust turbocharger (3) out of the crankcase and set it aside.
Catch and dispose of escaping coolant.

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Loosen screws (1) and (2).
Feed out the support (3) and remove it.

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Unlock and release the clamps (1) and (2).
Thread out positive battery cable (3) and set it aside.

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Loosen screws (1).
Feed out the transmission wiring harness (2) on the wiring harness section (3) for the sensor system 1 and set aside.

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Loosen screw (1).
Feed out the wiring harness section (2) for the sensor system 1 and set it aside.

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NOTE: The figure shows the rear of the engine.
Loosen screw (1).
Guide out and remove the cover (2).

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Loosen screws (1).
Guide out and remove slide rail (2).

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Unscrew the bearing journal (1) from the guide rail (2).

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Rotate the intake camshaft, if necessary, in the position shown.
The recess (2) must point upward.
Loosen screw (1).

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Slide the camshaft sensor wheel (1) in the direction of cylinder 1 and guide it out of the intake camshaft.

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Insert and position the special tool 2 459 012 at the cylinder head.

Tighten the screws (1) of special tool 2 459012.

TIGHTEN TORQUES SPECIFICATION

Special tool to cylinder head
M8	Tightening torque	21.5 Nm

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Release the cylinder head bolts in the sequence (5) to (1).

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Loosen the cylinder head bolts with the special tool 0 495 747 (11 8 580).

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Loosen the screws using special tool 0 495 747 (11 8 580) in the order (14) to (1).

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Feed out and remove all the cylinder head bolts (1).
Feed out and remove all the washers (2).

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CAUTION:
Heavy component.Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
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.
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Attach special tool 0 490 567 (11 0 020) to workshop crane.
Lift out the cylinder head (1) and the exhaust turbocharger with the help of a second person, using the workshop crane and the special tool 0 490 567 (11 0 020).