Removing the cylinder head

Preliminary work 

• Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
• Refer to DEACTIVATING THE 48 V ELECTRICAL SYSTEM .
• Disconnecting all battery ground leads. Refer to DISCONNECTING AND CONNECTING BATTERY GROUND LEAD
• Refer to REMOVING THE SEAL FOR THE HOOD REAR .
• 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 LEFT AND RIGHT WIPER ARM .
• Refer to REMOVING WINDSHIELD PANEL COVER .
• Refer to REMOVING THE CENTER COWL UPPER PART .
• Refer to REMOVING ACOUSTIC COVER AT REAR .
• Refer to REMOVING THE CENTER FIREWALL LOWERING PART .
• Refer to REMOVING SEAL FOR FRONT HOOD .
• Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
• Refer to IF INSTALLED: PARTIALLY REMOVING THE TOP RIGHT AND LEFT COVER IN THE ENGINE COMPARTMENT .
• Refer to REMOVING THE LEFT AND RIGHT FRONT-END STRUT .
• Refer to REMOVING UPPER CROSS CONNECTION .
• Refer to REMOVING THE REAR TOP CROSS CONNECTION .
• Refer to REMOVING THE FAN COWL .
• Refer to REMOVING INTAKE SILENCER HOUSING .
• Refer to REMOVING ENGINE VENTILATION LINE .
• Refer to REMOVING CLEAN AIR PIPE .
• Refer to REMOVING CHARGE AIR LINE .
• Refer to REMOVING THE ADAPTER FOR ENGINE VENTILATION LINE WITH HEATING ELEMENT ON EXHAUST TURBOCHARGER .
• Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
• Refer to REMOVING THE OXYGEN SENSOR MONITOR .
• Refer to REMOVING ALL IGNITION COILS .
• Refer to REMOVING ALL SPARK PLUGS .
• Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
• Refer to REMOVING FUEL DELIVERY LINE .
• 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 BOTH ACTUATORS .
• Refer to REMOVING THE CYLINDER HEAD COVER .
• Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
• Refer to REMOVING THE DME CONTROL UNIT .
• Refer to REMOVING THE CONTROL UNIT HOLDER .
• Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
• Refer to REMOVE THRUST FIELD .
• Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
• 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 REMOVING COMPLETE EXHAUST SYSTEM .
• Refer to REMOVING CATALYTIC CONVERTER .
• Refer to REMOVING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
• Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
• Refer to REMOVING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
• Refer to REMOVING TANK VENT VALVE .
• Refer to REMOVING THE INTAKE PLENUM .
• 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). 

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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 2 459 012.
  TIGHTENING TORQUE 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.

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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.
• 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).