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.

Feed in, position and install cylinder head (1) and 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.

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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 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) .

Fig 1: Cylinder Head Bolts Tightening Sequence

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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

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 SPECIFICATIONS

Camshaft sensor wheel to intake camshaft
M4x35	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 SPECIFICATIONS

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 SPECIFICATIONS

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 SPECIFICATIONS

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 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

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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 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.

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Connect connectors (1) and lock.

The connector (1) must engage audibly.

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Connect connectors (1) and lock.

The connector (1) must engage audibly.

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Replace the sealing ring (1) on the coolant feed line (2) for the turbocharger using the special tool 0 496 714 (00 9 030) .

Parts: Sealing ring

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Feed in and install the coolant feed line for the turbocharger (3) .
Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATIONS

Coolant feed line to crankcase
M6X12	tightening torque	8 Nm

Tighten down screw (2) .

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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 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 (1) for the 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 turbocharger.

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Feed in the screw (1) with the 2 470 546 special tool and apply and tighten hand-tight.

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

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Tighten screw (1) with the special tool 2 470 546 .

TIGHTENING TORQUE SPECIFICATIONS

Coolant return line/oil feed line to turbocharger
M6 x 12	tightening torque	8 Nm

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Connect and lock the coolant return line (1) for the 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

Turbocharger support to crankcase
M8 x 20 Replace screws.	Tightening torque	19 Nm

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Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATIONS

Turbocharger to support
M8 x 25	Tightening torque	19 Nm

Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATIONS

Coolant return line holder to crankcase
M6X12	tightening torque	8 Nm

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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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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 SECURING THE OIL SUMP ACOUSTIC COVER .
Refer to INSTALLING THE THERMOSTAT ON THE TRANSMISSION OIL LINES .
Refer to INSTALLING THE OIL RETURN LINE FOR THE 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 SECURING THE HIGH-VOLTAGE CABLES ON THE EME .
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 .
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 FRONT HOOD SEAL AT THE REAR .
Refer to INSTALLING THE DRIVE BELT FOR THE COOLANT PUMP .
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 FRONT CROSS CONNECTION (FRONT-END STRUT REMOVED) .
Refer to INSTALLING BOTH FRONT-END STRUTS .
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT CENTER .
Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
Refer to INSTALLING THE REAR DIFFUSER .
Refer to INSTALLING THE REAR AXLE COVER .
Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
Refer to IF INSTALLED: INSTALLING THE TORSION STRUT ON THE RIGHT, AND ON THE LEFT WHERE REQUIRED .
Refer to CONNECTING ALL BATTERY GROUND LEADS .
Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to CHECKING ENGINE OIL LEVEL .
Refer to CHECKING/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION .
Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING FRONT STIFFENING PLATE .
Refer to INSTALLING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT THRUST FIELD .
Refer to INSTALLING REAR UNDERBODY PROTECTION .
Refer to INSTALLING ACOUSTIC COVER .
Refer to TAKING HOOD OUT OF THE SERVICE POSITION .