Installing right cylinder head

• Make sure that there are no fluids or foreign material in the cylinder bores (1)  , remove if necessary.

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• Check the fitting sleeves (1)  for a correct fit and damage, replace if necessary.

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• Close oil hole in the area (1)  with a classification B plug from the set of special tools 2 364 711 .

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• Clean sealing surface (1) with special tool  0 495 103 (11 4 471)  from set of special tools  0 495 102 (11 4 470)  . 

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• Clean sealing surface (1) with special tool  0 495 104 (11 4 472)  from set of special tools  0 495 102 (11 4 470)  . 

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  NOTE: TECHNICAL INFORMATION 
  If there are foreign bodies or fluids present in the bores, the tightening torque values can be falsified.
• Clean bore holes (1)  of the cylinder head bolts with compressed air.

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• Clean sealing surface (1) with special tool  0 495 103 (11 4 471)  from set of special tools  0 495 102 (11 4 470)  . 

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• Clean sealing surface (1) with special tool  0 495 104 (11 4 472)  from set of special tools  0 495 102 (11 4 470)  . 

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• Replace cylinder head gasket (1)  .

  Parts:  Cylinder head gasket

• Replace screws.

  Parts:  Screws

• Position cylinder head gasket (1)  on the fitting sleeves on the engine block.

  If the cylinder head has been reworked, a thicker cylinder head gasket must be installed. 

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• Position cylinder head with a workshop crane.
  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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  NOTE: TECHNICAL INFORMATION 
  The work must be performed with vehicle care to prevent component damage.
• Insert cylinder head.
  NOTE: TECHNICAL INFORMATION 
  The work must be performed with vehicle care to prevent component damage.
• Detach special tool 0 490 567 (11 0 020) on the retaining tab (1) and on the special tool  0 493 997 (11 8 350)  . 

Tightening right cylinder head 

Tightening the right cylinder head 

• Tighten screws in the order (1)  to (10)  .

Cylinder head bolt
M11 Replace screws.	Joining torque	30 Nm
	1. Angle of rotation	90°
	2. Angle of rotation	140°

• Release the screw (1)  of the cylinder head cover.
• Remove standard nuts (M8) (2)  .
  NOTE: RISK OF DAMAGE 
  Damage of the engine and installed parts. 
  Non-compliance with the instructions for mounting and disassembly may lead to damage to the engine and installed parts. 

  • Comply with the regulations for the installation and disassembly.
  • Perform work with vehicle care.

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• Remove special tool 0 494 116 (11 8 352) (4)  .
• Check the centering sleeve on the cylinder head in the area (3)  for damage, replace if necessary.

Fastening cylinder head bolts on timing case cover 

• Secure the screws (1)  to the timing case cover.

Cylinder head bolt to timing case cover
M8x30	tightening torque	23 Nm

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Turn the intake camshaft back by 180° 

• Turn the intake camshaft (1)  back with an opened spanner (2)  by 180° against the direction of arrow.

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Mounting the special tool on the processed surface of the camshaft 

• Pay attention to the installation position:

  For the camshaft (1)  there are three machined surface. The special tool 2 249 117 can only be mounted in the marked position, (arrow).

• Mount special tool 2 249 117 .

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• Replace sealing ring (1)  .

  Parts:  Sealing ring

• Position sealing ring (1)  on the bearing bolt (2)  .

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• Position the slide rail.
• Tighten the screw (1)  of the slide rail on the cylinder head of the cylinder bank.

Slide rail to cylinder head
Bearing screw	Tightening torque	25 Nm

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Install both exhaust manifolds 

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• Clean sealing surfaces (1)  .
  NOTE: TECHNICAL INFORMATION 
  The sealing surfaces must be free of oil, grease and cleaning agents.

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  NOTE: TECHNICAL INFORMATION 
  Make sure that there are no particles or impurities in the medium openings. Coolant or foreign substances in the oil can cause engine damage such as damage to the connecting rod bearing.
  NOTE: RISK OF DAMAGE 
  Careless handling of tools and sharpened components. 
  Scratches, surface damage. 

  • Protect working area.
  • Handle tools and components carefully.
• Clean sealing surfaces (1)  .
• Replace seals (1)  .

  Parts:  Seals

• Position seals (1)  .

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  NOTE: TECHNICAL INFORMATION 
  The seals fit in one installation orientation only. Ensure correct installation.
• Install seal (1)  with the side of the bead (2)  (seal cavity) toward the exhaust manifold (3)  .

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• Position exhaust manifold (2)  .
• Replace screws (1)  .

  Parts:  Screws

• Tighten down screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Exhaust manifold
  M8x40 screw Replace screw.	tightening torque	25 Nm
  	Angle of rotation	45°

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• Position exhaust manifold (2)  .
• Replace screws (1)  .

  Parts:  Screws

• Tighten down screws (1)  .

Exhaust manifold
M8x40 screw Replace screw.	tightening torque	25 Nm
	Angle of rotation	45°

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• Slide the coolant hose on.
• Tighten the hose clamp (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Coolant ventilation line
  Hose clamp	Tightening torque	1.5 Nm

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• Secure the wiring harness mountings (1)  below the intake system.

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Follow-up work 

• Refer to INSTALLING BOTH VANOS ADJUSTERS (CYLINDER HEAD DISASSEMBLY, BANK 1) .
• Refer to INSTALLING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
• Refer to INSTALLING THE CYLINDER HEAD COVER ON THE RIGHT .
• Refer to INSTALLING THE VACUUM PUMP .
• Refer to INSTALLING HEAT SHIELD ON THE BOTTOM .
• Refer to INSTALLING FRONT HEAT SHIELD .
• Refer to INSTALLING BOTH EXHAUST MANIFOLDS .
• Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 1 TO 4 .
• Refer to INSTALLING LEFT AND RIGHT EXHAUST TURBOCHARGERS .
• Refer to MOUNTING FIXTURE ON THE RIGHT .
• Refer to INSTALLING LEFT MOUNT .
• Refer to INSTALLING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to INSTALLING CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to INSTALLING CATALYTIC CONVERTER NEAR THE ENGINE ABOVE CYLINDER BANK 1 .
• Refer to INSTALLING UPPER CATALYTIC CONVERTER NEAR ENGINE FOR BANK 2 .
• Refer to INSTALLING HEAT SHIELD, TOP .
• Installing conduit on bank 2.

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  • Clip the wiring harness (2) into the clamps (1).

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  • Position the wiring harness.
  • Tighten down screws (1).
    TIGHTENING TORQUES
    
    

    Cable duct
    M6x16 screw	Tightening torque	10Nm

• Refer to INSTALLING ENGINE VENTILATION LINE OF CYLINDER BANK 1 .
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE TANK VENTILATION LINE OF CYLINDER BANK 1 PARTIALLY .
• Installing cable duct at cylinder bank 1.

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  • Position the conduit (2).
  • Tighten the screws (1).
  TIGHTENING TORQUES
  
  

  Cable duct
  M6x16 screw	Tightening torque	10Nm

• Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 1 .
• Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
• Refer to CHECKING THE POSITION OF THE HEAT SHIELD .
• Refer to INSTALLING THE EXPANSION TANK FOR THE CHARGE AIR COOLER .
• Refer to INSTALLING COOLANT EXPANSION TANK .
• Refer to INSTALLING HOLDER OF THE DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
• Refer to INSTALLING ALTERNATOR .
• Refer to INSTALLING ELECTRIC COOLANT PUMP WITH HOLDER .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING RIGHT HIGH PRESSURE PUMP .
• Installing holder with the wiring harness for the sensor system of cylinder bank 2.

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  • Position the holder with the wiring harness for the sensor system.
  • Tighten screws (2).
    TIGHTENING TORQUES
    
    

    Holder of sensor system
    M6x16 screw	Tightening torque	10Nm

  • Connect plug connection (3) and lock.
  • Engage the coolant ventilation line in area (1) at the holder.
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE RIGHT TANK VENT VALVE .
• Refer to INSTALLING THE CHARGE AIR COOLER ON THE LEFT AND RIGHT .
• Refer to CLOSING THE COOLANT PUMPS .
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
• Refer to INSTALLING DRIVE BELT .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to INSTALLING THE FRONT RIGHT WHEEL .
• Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
• Refer to INSTALLING FAN COWL WITH ELECTRIC MOTOR .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING RIGHT INTAKE SILENCER HOUSING .
• Refer to INSTALLING LEFT INTAKE SILENCER HOUSING .
• Refer to INSTALLING FRONT CROSS CONNECTION .
• Refer to TIGHTENING THE LEFT FRONT-END STRUT .
• Refer to TIGHTENING THE FRONT-END STRUT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
• Refer to INSTALLING THE CENTER COWL UPPER PART .
• Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Installing the rear right engine compartment cover.

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  Remove the battery cover  .

  NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
  • Remove the special tool 2 452 007  from the battery.

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  • Install the cover (2).
  • Lock the lock (1).
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING THE COVER PANEL OF THE SLAVE DME CONTROL UNIT .
• Refer to INSTALLING THE COVER PANEL OF THE MASTER DME CONTROL UNIT .
• Refer to CONNECTING BATTERY GROUND LEAD .
• Refer to CHECKING ENGINE OIL LEVEL .