Installing the cylinder head

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 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.

NOTE: TECHNICAL INFORMATION
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 .

When removing and installing the cylinder head, make sure that the cylinder head does not damage the guide rail.

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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) .

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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 the cylinder head bolts with the special tools 0 495 747 (11 8 580) and 0 490 504 (00 9 120) in the sequence (1) to (14) .

Fig 1: Cylinder Head Bolts Tightening Sequence

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TIGHTENING TORQUE SPECIFICATION

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 SPECIFICATION

Cylinder head bolt to timing case cover
M8x40 Replace screws.	Tightening torque	19 Nm

Fig 2: Cylinder Head Bolts Tightening Sequence

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Feed in and position camshaft sensor wheel (1) on the intake camshaft (2) .

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Rotate the intake camshaft, if necessary, in the position shown.
The recess (2) must point upward.

Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Camshaft sensor wheel to intake camshaft
M4 x35	Tightening Torque	4.5 Nm

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Replace bearing journal (1) .
Parts: Bearing journal

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Feed in and install bearing journal (1) on the guide rail (2) .

Tighten the bearing journals (1) .

TIGHTENING TORQUE SPECIFICATION

Bearing journal to cylinder head
Bearing journal Replace the bearing journal!	Tightening torque	22 Nm

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Insert slide rail (2) and install.

Tighten down screws (1) .

TIGHTENING TORQUE SPECIFICATION

Sliding rail to cylinder head
M6x16	Tightening Torque	8 Nm

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Guide in and install cover (2) .

Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Cover to rear cylinder head
M6	tightening torque	8 Nm

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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.

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Guide in and install the wiring harness section (2) for sensor system 1.

Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Cable bracket on rear cylinder head/transmission
M6x20	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) .

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TIGHTENING TORQUE SPECIFICATION

Cable bracket on rear cylinder head/transmission
M6x20	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) .

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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 (2) must engage audibly.
Insert and position the wiring harness section (4) for the sensor system 1 .
Secure clamps (3) .
Connect and lock coolant line (1) .
Make sure that the coolant line (1) engages audibly.

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Connect connectors (1) and lock.
The connector (1) must engage audibly.

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Replace the sealing rings (1) at the oil feed line (2) for the exhaust turbocharger using the special tool 0 496 714 (00 9 030) .
Parts: Sealing ring

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Feed in and install the oil feed line (2) for the exhaust turbocharger.

Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Oil feed line for exhaust turbocharger to crankcase
M6x12 Replace sealing ring	tightening torque	8 Nm

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Tighten screw (1) on the coolant return line (2) .

TIGHTENING TORQUE SPECIFICATION

Coolant return line holder to crankcase
M6X12	tightening torque	8 Nm

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Connect and lock the coolant return line (1) to the coolant pump (2) for the exhaust turbocharger.
The coolant return line (1) must engage audibly.

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Connect and lock the coolant return line (1) for the exhaust turbocharger.
Make sure that the coolant return line (1) engages audibly.
Feed in and install the heat shield (2) .

Replace screws (1) .

Parts: Screws

Tighten down screws (1) .

TIGHTENING TORQUE SPECIFICATION

Heat shield to cylinderhead
M8X12 Replace screws.	tightening torque	19 Nm

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Feed in and install the heat shield (3) .

Replace screws (1) .

Parts: Screws

Tighten down screws (1) .

TIGHTENING TORQUE SPECIFICATION

Heat shield to cylinder head
M8X12 Replace screws.	tightening torque	19 Nm

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Replace the screw (2) .

Parts: Screw

Tighten down screw (2) .

TIGHTENING TORQUE SPECIFICATION

Heat shield to trim strip
M6X16 Replace screw.	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.

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Replace the sealing rings (1) on the coolant feed line (2) for the exhaust turbocharger using the special tool 0496 714 (00 9 030) .
Parts: Sealing ring

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Feed in and install the coolant feed line for the exhaust turbocharger (3) .

Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Coolant feed line to crankcase
M6X12	tightening torque	8 Nm

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Tighten down screw (2) .

TIGHTENING TORQUE SPECIFICATION

Coolant feed line to crankcase
M6X12	tightening torque	8 Nm

Replace screws (1) and (2) .
Parts: Screws
Feed in and install support (3) .

Tighten down screws (2) .

TIGHTENING TORQUE SPECIFICATION

Exhaust turbocharger support to crankcase
M8x20 Replace screws.	Tightening Torque	19 Nm

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Tighten down screws (1) .

TIGHTENING TORQUE SPECIFICATION

Exhaust turbocharger to support
M8x25 Replace screw.	Tightening Torque	19 Nm

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 INTAKE PLENUM .
Refer to INSTALLING THE TANK VENT VALVE .
Refer to INSTALLING CONTROL UNIT BRACKET .
Refer to INSTALLING THE DME CONTROL UNIT .
Refer to INSTALLING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
Refer to INSTALLING THE COOLANT LINE BETWEEN THE CYLINDER HEAD AND THE COOLANT PUMP .
Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING CATALYTIC CONVERTER .
Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
Refer to IF INSTALLED: SECURING THE ENGINE OIL COOLER .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to INSTALLING BOTH ACTUATORS .
Refer to INSTALLING HIGH PRESSURE PUMP .
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 THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
Refer to INSTALLING FUEL DELIVERY LINE .
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 ADAPTER FOR THE ENGINE VENTILATION LINE WITH THE HEATING ELEMENT ON THE EXHAUST TURBOCHARGER .
Refer to INSTALLING CHARGE AIR LINE .
Refer to INSTALLING CLEAN AIR PIPE .
Refer to INSTALLING ENGINE VENTILATION LINE .
Refer to INSTALLING INTAKE FILTER HOUSING .
Refer to INSTALLING FAN COWL .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING UPPER CROSS CONNECTION .
Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
Refer to IF INSTALLED: INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT (PARTIALLY REMOVED) .
Refer to INSTALLING THE COVER FOR CENTER ENGINE COMPARTMENT .
Refer to INSTALLING THE FRONT HOOD SEAL .
Refer to CONNECTING ALL BATTERY GROUND LEADS .
Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .
Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to CHECKING THE HIGH-TEMPERATURE COOLING SYSTEM FOR WATERTIGHTNESS .
Refer to CHECKING LOW-TEMPERATURE COOLING SYSTEM FOR WATERTIGHTNESS .
Refer to CHECKING ENGINE OIL LEVEL .
Refer to INSTALLING CENTER FIREWALL LOWERING PART .
Refer to INSTALLING ACOUSTIC COVER AT REAR .
Refer to INSTALLING THE CENTER COWL UPPER PART .
Refer to INSTALLING WINDSHIELD PANEL COVER .
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING THE REAR HOOD SEAL .
Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to TAKING HOOD OUT OF THE SERVICE POSITION .