Installing the cylinder head
CAUTION:
Heavy component
.
Heavy components can lead to injury or damage .
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 threads .
Fluids in the threaded hole can damage the thread if screws in it are tightened .
Damage to threads .
Fluids in the threaded hole can damage the thread if screws in it are tightened .
- Dry threaded holes (e.g. using compressed air).
NOTE:
TECHNICAL INFORMATION
Do not remove screw coating.
Do not remove screw coating.
NOTE:
TECHNICAL INFORMATION
When replacing the cylinder head: The complete valve timing and the Valvetronic servomotor are already pre-assembled for new cylinder heads.
When replacing the cylinder head: The complete valve timing and the Valvetronic servomotor are already pre-assembled for new cylinder heads.
NOTE:
RISK OF DAMAGE
Damage to guide rails .
The application of great force can damage the guide rails of the timing chain .
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.
- Feed in, position and install cylinder head (1) and exhaust turbocharger with the help of an auxiliary person, the workshop crane and the special tool 0 490 567 (11 0 020) .
- Ensure that the guide rails of the timing chain are not damaged.
- Insert and install washer (2) .
- Replace the cylinder head bolts (1)
.
Parts: Cylinder head bolts
- Do not wash off the coating (1) of the cylinder head bolts .
- Lightly
oil contact surfaces of cylinder head bolt screw heads.
There must be no coolant, water or engine oil in the threaded holes of the crankcase.
- Guide in and install cylinder head bolts (1)
.NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Failure to comply with the regulations can lead to leaks and damage. - Screw in the cylinder head bolts in the sequence (1) to (14).
- Tighten cylinder head bolts with special tool 0 495 747 (11 8 580) and 0 490 504 (00 9 120)
in the
order (1)
to (14)
.TIGHTENING TORQUE SPECIFICATIONS
Cylinder head to crankcase M11
Observe tightening sequence!
Fit new cylinder head bolts.1. Joining torque 30 Nm 2. Angle of rotation 90° 3. Angle of rotation 180° - Replace cylinder head bolts (1)
to (5)
.
Parts: Cylinder head bolts
- Make sure that there is no coolant, water or engine oil in the threaded holes of the timing case cover.
- Screw in cylinder head bolts (1) to (5) .
- Tighten the cylinder head bolts in the sequence (1)
to (5)
.TIGHTENING TORQUE SPECIFICATIONS
Cylinder head bolt to timing case cover M8x40
Replace screws.Tightening torque 19 Nm - Feed in and position camshaft sensor wheel (1)
on the intake camshaft (2)
.
- Rotate the intake camshaft, if necessary, in the position shown.
The recess (2) must point upward.
- Tighten down screw (1)
.TIGHTENING TORQUE SPECIFICATIONS
Camshaft sensor wheel to intake camshaft M4 x35 Tightening torque 4.5 Nm - Replace bearing journal (1)
.
Parts: Bearing journal
- Feed in and install bearing journal (1) on the guide rail (2) .
- Tighten the bearing journals (1)
.TIGHTENING TORQUE SPECIFICATIONS
Bearing journal to cylinder head Bearing journal
Replace the bearing journal!Tightening torque 22 Nm - Insert slide rail (2) and install.
- Tighten down screws (1)
.TIGHTENING TORQUE SPECIFICATIONS
Sliding rail to cylinder head M6x16 Tightening torque 8 Nm - Guide in and install cover (2) .
- Tighten down screw (1)
.TIGHTENING TORQUE SPECIFICATIONS
Cover to rear cylinder head M6 Tightening torque 8 Nm NOTE: RISK OF DAMAGE
Improper routing of cables and wiring harnesses .
Trapped, crushed or damaged cables may cause short circuits and malfunctions .- Route all cables without abrasions, do not trap and crush.
- Guide in and install the wiring harness section (2) for sensor system 1.
- Tighten down screw (1)
.TIGHTENING TORQUE SPECIFICATIONS
Cable bracket on rear cylinder head/transmission M6 x 20 tightening torque 8 Nm NOTE: RISK OF DAMAGE
Improper routing of cables and wiring harnesses .
Trapped, crushed or damaged cables may cause short circuits and malfunctions .- Route all cables without abrasions, do not trap and crush.
- Guide in and install the transmission wiring harness (2) on the wiring harness section (3) for sensor system 1.
- Tighten down screws (1)
.TIGHTENING TORQUE SPECIFICATIONS
Cable bracket on rear cylinder head/transmission M6 x 20 tightening torque 8 Nm CAUTION: Improper routing of the positive battery cable .
Risk of short circuits!- Route the positive battery cable without abrasions and do not trap.
- Insert and install the positive battery cable (3) .
- Secure clamps (1)
and (2)
.NOTE: RISK OF DAMAGE
Improper routing of cables and wiring harnesses .
Trapped, crushed or damaged cables may cause short circuits and malfunctions .- Route all cables without abrasions, do not trap and crush.
- Connect connectors (2)
and lock.
The connector must engage audibly.
- Guide in and position the wiring harness section (4) of sensor system 1.
- Secure clamps (3) .
- Connect and lock coolant line (1) .
- Make sure that the coolant line (1) engages audibly.
- Connect connectors (1)
and lock.
The connector (1) must engage audibly.
- Connect connectors (1)
and lock.
The connector (1) must engage audibly.
- Replace the sealing ring (1)
on the coolant feed line (2) for the exhaust turbocharger using the special tool 0 496 714 (00 9 030)
.
Parts: Sealing ring
- Feed in and install the coolant feed line for the exhaust turbocharger (3) .
- Tighten down screw (1)
.TIGHTENING TORQUE SPECIFICATIONS
Coolant feed line to crankcase M6X12 tightening torque 8 Nm - Tighten down screw (2)
.TIGHTENING TORQUE SPECIFICATIONS
Coolant feed line to crankcase M6X12 tightening torque 8 Nm - Replace the sealing ring (1)
at the oil feed line (2)
for the exhaust turbocharger using the special tool 0 496 714 (00 9 030)
.
Parts: Sealing ring
- Feed in and install the oil feed line (1) for the exhaust turbocharger.
- Replace sealing ring on coolant return line (2)
with special tool 0 496 714 (00 9 030)
.
Parts: Sealing ring
- Guide in and install the coolant return line (2)
for the exhaust turbocharger.
- Feed in the screw (1)
with the 2 470 546
special tool and apply and tighten hand-tight.
- Position special tool 2 470 546
on the screw (1)
.
- Tighten screw (1)
with the special tool 2 470 546
.TIGHTENING TORQUE SPECIFICATIONS
Coolant return line/oil feed line to exhaust turbocharger M6 x 12 tightening torque 8 Nm - Connect and lock the coolant return line (1) for the exhaust turbocharger.
- Make sure that the coolant return line (1) engages audibly.
- Replace screw (1)
and (2)
.
Parts: Screws
- Feed in the support (3) and position it.
- Tighten down screws (2)
.TIGHTENING TORQUE SPECIFICATIONS
Exhaust turbocharger support to crankcase M8 x 20
Replace screws.tightening torque 19 Nm - Tighten down screw (1)
.TIGHTENING TORQUE SPECIFICATIONS
Exhaust turbocharger to support M8 x 25
Replace screw.tightening torque 19 Nm - Tighten down screw (1)
.TIGHTENING TORQUE SPECIFICATIONS
Coolant return line holder to crankcase M6X12 tightening torque 8 Nm - Unscrew the bolts (1) of the special tool 2 459 012 .
- Feed out the special tool 2 459 012 at the cylinder head and remove.
Follow-up work
- Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
- Refer to INSTALLING THE INTAKE ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to DISASSEMBLING ALL SPECIAL TOOLS .
- Refer to INSTALLING CHAIN TENSIONER .
- Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
- Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to INSTALLING CATALYTIC CONVERTER .
- Refer to INSTALLING THE COOLANT LINE BETWEEN THE CYLINDER HEAD AND THE COOLANT PUMP .
- Refer to INSTALLING THE INTAKE PLENUM .
- Refer to INSTALLING THE TANK VENT VALVE .
- Refer to INSTALLING CONTROL UNIT BRACKET .
- Refer to INSTALLING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
- Refer to INSTALLING THE DME CONTROL UNIT .
- Refer to INSTALLING CYLINDER HEAD COVER .
- Refer to INSTALLING BOTH ACTUATORS .
- Refer to PREPARING THE INJECTORS FOR INSTALLATION .
- Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
- Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 1 TO 3 .
- Refer to INSTALLING HIGH PRESSURE PUMP .
- Refer to INSTALLING FUEL DELIVERY LINE .
- Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
- Refer to INSTALLING ALL SPARK PLUGS .
- Refer to INSTALLING ALL IGNITION COILS .
- Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
- Refer to INSTALLING LAMBDA OXYGEN SENSOR .
- Refer to INSTALLING THE HOLDER OF THE POSITIVE BATTERY CABLE .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING THE CENTER COWL UPPER PART .
- Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
- Refer to ATTACHING WINDSHIELD PANEL COVER .
- Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
- Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
- Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
- Refer to INSTALLING THE REAR HOOD SEAL .
- Refer to INSTALLING CHARGE AIR LINE .
- Refer to INSTALLING BOTTOM CLEAN AIR PIPE .
- Refer to INSTALLING THE RESONATOR WITH THE TOP CLEAN AIR PIPE .
- Refer to INSTALLING THE INTAKE FILTER HOUSING (TENSION STRUT REMOVED ON SHOCK TOWER) .
- Refer to INSTALLING FAN COWL .
- Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
- Refer to INSTALLING UPPER CROSS CONNECTION .
- Refer to INSTALLING BOTH FRONT-END STRUTS .
- Refer to INSTALLING THE CENTER ENGINE COMPARTMENT COVER .
- Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
- Refer to INSTALLING THE REAR DIFFUSER .
- Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
- Refer to INSTALLING THE TORSION STRUT ON THE REAR LEFT AND RIGHT .
- Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
- Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
- Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
- Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
- Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to CHECKING ENGINE OIL LEVEL .
- Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
- Refer to INSTALLING THE FRONT BOTTOM LEFT AND RIGHT COVER .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .
- Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT THRUST FIELD .
- Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
- Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to TAKING HOOD OUT OF THE SERVICE POSITION .