Removing the cylinder head: Notes

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 .

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

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 WINDSHIELD PANEL COVER .
Refer to REMOVING TRAILING LINK AT SPRING BOLT .
Refer to REMOVING THE COWL UPPER PART IN THE CENTER .
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 CENTER ENGINE COMPARTMENT COVER .
Refer to REMOVING BOTH FRONT-END STRUTS .
Refer to REMOVING UPPER CROSS CONNECTION .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE 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 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 .
Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR AND THRUST FIELD RESPECTIVELY .
Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to REMOVING THE FRONT BOTTOM RIGHT AND LEFT COVERS .
Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY .
Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to REMOVING THE TORSION STRUT ON THE REAR LEFT AND RIGHT .
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 EXHAUST 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 LINES FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to CONNECTING THE COOLANT LINES FOR THE 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 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 .

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 workshop crane 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 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.

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Loosen screw (1).

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

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

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

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

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

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

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Unlock plug connection (1) and disconnect.

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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 sensor system 1 and place to one side.

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

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

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Shift the camshaft sensor wheel (1) in direction of cylinder 1 and feed out from 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 the special tool 2 459 012 .

TIGHTENING TORQUE SPECIFICATIONS

Special tool to cylinder head
M8	Tightening torque	21.5 Nm

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

Fig 1: Cylinder Head Bolts Loosening Sequence
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Loosen the cylinder head bolts with the special tool 0 495 747 (11 8 580) .

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

Fig 2: Cylinder Head Bolts Loosening Sequence
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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.
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) .

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