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.

Position the cylinder head (1) on the special tool 0 490 561 (11 0 000) and on the workshop crane .

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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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Guide in and install the cylinder head (1) carefully using the workshop crane and the special tool 0 490 561 (11 0 000) .
Replace cylinder head bolts (1) to (10) .
Parts: Cylinder head bolts
Do not wash off the coating on the cylinder head bolts (1) to (10) .
Oil the contact surfaces of the screw heads of cylinder head bolts (1) to (10) lightly .
There must be no coolant, water or engine oil present in the threaded holes of the engine block.

Fig 1: Cylinder Head Bolts Tightening Sequence
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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.
Insert and install cylinder head bolts (1) to (10) .
Screw in the cylinder head bolts in the sequence (1) to (10) .

Tighten the cylinder head bolts with the special tools 0 490 504 (00 9 120) and 0 495 747 (11 8 580) in the sequence (1) to (10) .

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.

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

Fig 2: Cylinder Head Bolts Tightening Sequence

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TIGHTENING TORQUE SPECIFICATIONS

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

Insert and install the camshaft sensor wheel (3) .
Ensure that the camshaft wheel (3) is correctly positioned on the guide pin (4) .
Affix the intake camshaft with an open-end wrench (1) .

Tighten down screw (2) .

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TIGHTENING TORQUE SPECIFICATIONS

Camshaft sensor wheel to intake camshaft
M6x16 Replace screw.	1. Tightening torque	5 Nm
	2. Angle of rotation	90°

Position the guide rail (2) .
Replace bearing journal (1) .
Parts: Bearing journal
Thread in the bearing journals (1) and install.
Make sure that the bearing journal (1) is correctly installed in the guide rail (2) .

Tighten the bearing pin (1) to the guide rail (2) .

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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Insert and position the wiring harness section (2) for sensor system 1 .

Tighten down screws (1) .

TIGHTENING TORQUE SPECIFICATIONS

Wiring harness section for sensor system 1 to cylinder head
Screw M6	Tightening torque	8 Nm

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Feed in ground cable (4) and position.

Tighten down screw (3) .

TIGHTENING TORQUE SPECIFICATIONS

Ground cable to cylinder head
M6X16	Tightening torque	8 Nm

Feed in and install coolant line (1) .

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Insert and install the holder (2) .
Make sure that the lock (1) engages audibly.

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Insert and install the holder (2) .
Tighten down screw (1) .

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Connect and lock the coolant line (1) to the cylinder head.
Make sure that the coolant line (1) engages audibly.
Connect the connector (2) to the coolant temperature sensor and lock it.
Ensure that the connector (2) audibly engages on the coolant temperature sensor.

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Feed in and install coolant line (2) .

Tighten down screws (1) .

TIGHTENING TORQUE SPECIFICATIONS

Coolant line to coolant pump/cylinder head
M6x20	Tightening torque	8 Nm

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Loosen the screws (1) from the special tool 2 459 012 .
Guide the special tool 2 459 012 out and remove.

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Follow-up work

Refer to INSTALLING THE RIGHT ENGINE MOUNT .
Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to INSTALLING THE INTAKE ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to DISASSEMBLING ALL SPECIAL TOOLS .
Refer to INSTALLING CHAIN TENSIONER .
Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to ROTATING THE CAM OF THE HIGH-PRESSURE PUMP DRIVE TO THE BDC POSITION .
Refer to INSTALLING HIGH PRESSURE PUMP .
Refer to INSTALLING BOTH ACTUATORS .
Refer to PREPARING THE INJECTORS FOR INSTALLATION .
Refer to INSTALLING INJECTORS .
Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE RAIL AND THE HIGH-PRESSURE PUMP .
Refer to INSTALLING ALL SPARK PLUGS .
Refer to INSTALLING THE IGNITION COILS .
Refer to CONNECTING COOLANT LINE .
Refer to INSTALLING THE SERVOMOTOR FOR THE ECCENTRIC SHAFT .
Refer to INSTALLING THE INTAKE PLENUM .
Refer to INSTALLING THE TANK VENT VALVE .
Refer to INSTALLING FAN COWL WITH ELECTRIC FAN .
Refer to INSTALLING FRONT CROSS CONNECTION .
Refer to PREPARING FOR THE INSTALLATION OF THE EXHAUST TURBOCHARGER .
Refer to INSTALLING EXHAUST TURBOCHARGER .
Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING CATALYTIC CONVERTER .
Refer to PREPARING THE PROP SHAFT .
Refer to INSTALLING PROP SHAFT .
Refer to INSTALLING THE REAR HEAT SHIELD .
Refer to INSTALLING FRONT HEAT SHIELD .
Refer to INSTALLING EXHAUST SYSTEM .
Refer to INSTALLING THE CONNECTING SUPPORT ON THE TUNNEL AT FRONT AND REAR .
Refer to INSTALLING THE CROSS-MEMBER WITH TORSION STRUTS .
Refer to INSTALLING WASHER FLUID RESERVOIR .
Refer to PARTIALLY INSTALLING THE FRONT WHEEL ARCH COVER .
Refer to INSTALLING THE FRONT RIGHT WHEEL ARCH COVER .
Refer to INSTALLING THE FRONT RIGHT WHEEL .
Refer to EVACUATE AND CHARGE CONDITIONING .
Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
Refer to INSTALLING LAMBDA OXYGEN SENSOR .
Refer to INSTALLING RIGHT REAR SUSPENSION CROSS-BRACE .
Refer to PREPARING FOR THE INSTALLATION OF THE CLEAN AIR PIPE .
Refer to INSTALLING CLEAN AIR PIPE .
Refer to IF INSTALLED: PARTIALLY INSTALLING ENGINE VENTILATION LINE .
Refer to INSTALLING THE REAR BULKHEAD .
Refer to INSTALLING INTAKE SILENCER HOUSING .
Refer to INSTALLING THE INTAKE MANIFOLD FOR THE INTAKE FILTER HOUSING .
Refer to INSTALLING THE UPPER FIREWALL COVER PANEL .
Refer to INSTALLING THE STRUT BRACE .
Refer to FILLING THE COOLANT CIRCUIT WITH THE VACUUM FILLING EQUIPMENT .
Refer to CONNECTING THE BATTERY EARTH LEAD .
Refer to AIR BLEEDING THE COOLANT CIRCUIT .
Refer to INSTALLING THE FRONT UNDERBODY PROTECTION .
Refer to INSTALLING ACOUSTIC COVER .
Refer to CHECKING ENGINE OIL LEVEL .