Removing the cylinder head

DANGER 

High-voltage system. 

The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock! 

• All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
• For additional information see: 61 00... SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS .
• For additional information see: 61 25... NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT .

Preliminary work 

• Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVING THE ACOUSTIC COVER .
• Refer to REMOVING THE SEAL FOR THE HOOD REAR .
• Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT .
• Refer to REMOVING THE COVER OF THE REAR RIGHT ENGINE COMPARTMENT .
• Refer to REMOVING LEFT AND RIGHT WIPER ARM .
• Refer to REMOVING THE COWL COVER .
• Refer to REMOVING TRAILING LINK AT SPRING BOLT .
• Refer to REMOVING THE CENTER COWL UPPER PART .
• Refer to RELEASING THE HIGH-VOLTAGE CABLES ON THE EME .
• Refer to REMOVING ACOUSTIC COVER AT REAR .
• Refer to REMOVING BOTH ACTUATORS .
• Refer to REMOVING ALL IGNITION COILS .
• Refer to REMOVING ALL SPARK PLUGS .
• Refer to REMOVING FUEL DELIVERY LINE .
• Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
• Refer to REMOVING HIGH PRESSURE PUMP .
• Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 1 TO 3 .
• Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 4 TO 6 .
• Refer to REMOVING THE CYLINDER HEAD COVER .
• Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
• Refer to REMOVING BOTH FRONT-END STRUTS .
• Refer to REMOVING FRONT CROSS CONNECTION (FRONT-END STRUT REMOVED) .
• Refer to REMOVING THE REAR TOP CROSS CONNECTION .
• Refer to REMOVING FAN COWL .
• Refer to REMOVING THE INTAKE FILTER HOUSING (TENSION STRUT ON SHOCK TOWER REMOVED) .
• Refer to REMOVING THE RESONATOR WITH THE TOP CLEAN AIR PIPE .
• Refer to REMOVING BOTTOM CLEAN AIR PIPE .
• Refer to REMOVING CHARGE AIR LINE .
• Refer to REMOVING THE DRIVE BELT FOR COOLANT PUMP .
• Refer to REMOVING THE HOLDER OF THE POSITIVE BATTERY CABLE .
• Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
• Refer to REMOVING THE OXYGEN SENSOR MONITOR .
• Refer to REMOVING THE DME CONTROL UNIT .
• Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
• Refer to REMOVING CONTROL UNIT BRACKET .
• Refer to REMOVING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
• Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR AND THRUST FIELD RESPECTIVELY .
• Refer to REMOVING THE FRONT THRUST FIELD .
• Refer to REMOVING THE STIFFENING PLATE .
• Refer to REMOVING REAR UNDERBODY PROTECTION .
• Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY .
• Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
• Refer to IF INSTALLED: REMOVING THE TORSION STRUT ON THE RIGHT AND LEFT WHERE REQUIRED .
• Refer to REMOVING THE REAR AXLE COVER .
• Refer to REMOVING THE REAR DIFFUSER .
• Refer to REMOVING COMPLETE EXHAUST SYSTEM .
• Refer to REMOVING CATALYTIC CONVERTER .
• Refer to REMOVING THE OIL RETURN LINE FOR THE TURBOCHARGER .
• Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
• Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to CONNECTING THE COOLANT LINE OF HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to CONNECTING THE COOLANT LINE OF LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to REMOVING TANK VENT VALVE .
• Refer to REMOVING THE INTAKE PLENUM .
• Refer to REMOVING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
• Refer to REMOVING THE THERMOSTAT FROM THE TRANSMISSION OIL LINES .
• Refer to PARTIALLY RELEASING OIL SUMP ACOUSTIC COVER .
• Refer to BLOCKING ENGINE IN TDC FIRING POSITION .
• Refer to REMOVING CHAIN TENSIONER .
• Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
• Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
• Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
• Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
• Refer to REMOVING INTAKE ADJUSTER .
• Refer to REMOVING EXHAUST CAMSHAFT ADJUSTER .
• Refer to REMOVING THE TEST GAUGES FOR SECURING THE CAMSHAFTS .

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

  Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare the workshop crane 2 220 718 .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Unlock plug connection (1)  and disconnect.

  Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

• Loosen screw (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position special tool 2 470 546 on the screw (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Release the screw (1)  using the special tool 2 470 546. 

Courtesy of BMW OF NORTH AMERICA, INC.

• Feed out the screw (1)  using special tool 2 470 546 and remove.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Feed out the coolant return line (2)  for the turbocharger and set it aside.
• Feed out the oil feed line (1)  for the turbocharger and set it aside.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Loosen screws (1)  and (2)  .
• Feed the coolant feed line for the turbocharger (3)  out of the crankcase and place aside.
• Catch and dispose of leakage coolant.

Courtesy of BMW OF NORTH AMERICA, INC.

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

  Courtesy of BMW OF NORTH AMERICA, INC.

• Unlock plug connection (1)  and disconnect.

  Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

• Loosen screws (1)  .
• Feed out the transmission wiring harness (2)  on the wiring harness section (3)  for sensor system 1 and place to one side.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Loosen screw (1)  .
• Feed out the wiring harness section (2)  for sensor system 1 and place to one side.

  Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

  Courtesy of BMW OF NORTH AMERICA, INC.

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

  Courtesy of BMW OF NORTH AMERICA, INC.

• Rotate intake camshaft, if necessary in the position shown.

  The recess (2)  must point up.

• Loosen screw (1)  .

Courtesy of BMW OF NORTH AMERICA, INC.

• Shift the camshaft sensor wheel (1)  in direction of cylinder 1 and feed out from the intake camshaft.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Insert and position the special tool 2 459 012 at the cylinder head.
• Tighten the screws (1)  of the special tool 2 459 012 .

Special tool to cylinder head
M8	tightening torque	21.5 Nm

• Loosen the cylinder head bolts in the sequence from (5)  to (1)  .

Courtesy of BMW OF NORTH AMERICA, INC.

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

  Courtesy of BMW OF NORTH AMERICA, INC.

• Undo the screws using the special tool 0 495 747 (11 8 580) in the order (14) to (1). 
  Fig 2: Cylinder Head Screw Loosening Sequence

  Courtesy of BMW OF NORTH AMERICA, INC.
• Feed out and remove all the cylinder head bolts (1)  .
• Feed out and remove all the washers (2)  .

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

• Attach special tool 0 490 567 (11 0 020) to workshop crane.
• Lift out the cylinder head (1)  and the turbocharger with the help of a second person, using the workshop crane and the special tool 0 490 567 (11 0 020) .