Removing the cylinder head

WARNING: 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: SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS .
For additional information see: NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT .

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.

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.

Preliminary work

Refer to REMOVING FLAP IN LUGGAGE COMPARTMENT TRIM PANEL ON RIGHT .
Refer to DE-ENERGIZING THE HIGH-VOLTAGE SYSTEM
Refer to CHECKING THAT NO VOLTAGE IS APPLIED
Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE (STARTER UNIT BATTERY) .
Refer to REMOVING BATTERY COVER IN TRUNK .
Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE OF THE SYSTEM BATTERY
Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
Refer to REMOVING THE ACOUSTIC COVER .
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 THE SEAL FOR THE HOOD REAR .
Refer to REMOVING LEFT AND RIGHT WIPER ARM .
Refer to REMOVING THE COWL COVER .
Refer to REMOVING THE TENSION STRUT AT THE SHOCK TOWER ON THE LEFT AND RIGHT .
Refer to REMOVING THE FIRE WALL UPPER PART .
Refer to RELEASING THE HIGH-VOLTAGE CABLES ON THE EME .
Refer to REMOVING THE SECOND FIRE WALL AT THE BOTTOM .
Refer to REMOVING ACOUSTIC COVER AT REAR .
Refer to REMOVING RESONATOR .
Refer to REMOVING CLEAN AIR PIPE .
Refer to REMOVING CHARGE AIR LINE .
Refer to REMOVING THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT .
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 CYLINDER HEAD COVER ACOUSTIC COVER .
Refer to REMOVING ALL IGNITION COILS .
Refer to REMOVING ALL SPARK PLUGS .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
Refer to REMOVING THE RAIL WITH INJECTORS .
Refer to REMOVING FUEL DELIVERY LINE .
Refer to REMOVING HIGH PRESSURE PUMP .
Refer to REMOVING THE HOLDER OF THE POSITIVE BATTERY CABLE .
Refer to REMOVING THE HEAT SHIELD AT THE CYLINDER HEAD .
Refer to REMOVING BOTH ACTUATORS .
Refer to REMOVING THE CYLINDER HEAD COVER .
Refer to REMOVING TANK COVER ON LEFT AND RIGHT .
Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to REMOVING EXHAUST SYSTEM .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY .
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 LINES FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to CONNECTING THE COOLANT HOSE OF THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to REMOVING CATALYTIC CONVERTER .
Refer to REMOVING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to REMOVING THE COOLANT FEED LINE FOR THE EXHAUST GAS TURBOCHARGER .
Refer to REMOVING THE COOLANT RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to REMOVING TANK VENTING VALVE .
Refer to REMOVING THE INTAKE PLENUM .
Refer to REMOVING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
Refer to RELEASING THE EPS WIRING HARNESS FROM THE ELECTROMECHANICAL STEERING GEAR .
Refer to REMOVING THE THERMOSTAT FROM THE TRANSMISSION OIL LINES .
Refer to REMOVING THE HOLDER FOR THE THERMOSTAT ON THE TRANSMISSION OIL LINE .
Refer to BLOCKING ENGINE IN TDC FIRING POSITION .
Refer to REMOVING CHAIN TENSIONER .
Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to REMOVING EXHAUST CAMSHAFT ADJUSTER .
Refer to REMOVING INTAKE ADJUSTER .
Refer to REMOVING THE TEST GAUGES FOR SECURING THE CAMSHAFTS .

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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Loosen screw (1).
Release the oil feed line (2) on the exhaust turbocharger.

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Feed out the oil feed line (1) in the arrow direction on the exhaust turbocharger (2) and set aside.

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Loosen nut (1).
Feed out ground cable (2) and set it aside.

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Loosen screw (1).
Loosen screw (2).
Thread out holder (3) and set aside.

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Loosen screws (1).
Thread out holder (2) and set aside.

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Unlock plug connection (1) and disconnect.

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Unlock and loosen coolant line (1).
Unlock and disconnect the plug connection (2) on the knock sensor.
Unlock and disconnect the plug connection (3) on the coolant temperature sensor.

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

TIGHTENING TORQUES SPECIFICATION

Special tool to cylinder head
M8	Tightening torque	21.5 Nm

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Fasten the intake camshaft (2) with a standard open-end wrench (1).
Loosen screw (3).
Feed out and remove the camshaft sensor wheel (4) on the guide pin (5).

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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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Release the cylinder head bolts with the special tool 0 495 747 (11 8 580) in the sequence (10) 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.

Hook the special tool 0 490 567 (11 0 020) on the special tool 2 220 718 .
Lift out the cylinder head (1) and the exhaust turbocharger with the help of a support person , with the special tool 2 220 718 and the special tool 0 490 567 (11 0 020) .
Ensure that the guide rails of the timing chain are not damaged.

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