Remove right cylinder head

Precondition

Ignition is switched off.

WARNING: Hot surfaces .
Risk of burning!

Perform all work only on components that have cooled down.

WARNING: Hot fluids .
Risk of scalding!

Conduct all work in the vehicle wearing appropriate personal protective equipment only.

CAUTION: Materials harmful to health .
Contact with fluids harmful to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

NOTE: RISK OF DAMAGE
Careless handling of tools and sharp-edged components .
Scratches, surface damage .

Protect working area.
Handle tools and components carefully.

NOTE: TECHNICAL INFORMATION
Notes for working on the engine cooling system.
For additional information see: NOTES FOR WORKING ON THE COOLING SYSTEM .

NOTE: TECHNICAL INFORMATION
Immobilization period-long fill of coolant!
Do not reuse used coolant.
The coolant must be replaced when replacing and removing components which depend on the anti-corrosion effect of the coolant. The cooling system must therefore be emptied and refilled.
In the case of other removal work involving the draining of part quantities of coolant, the coolant level must be topped up with new coolant.

NOTE: TECHNICAL INFORMATION
Filling without the vacuum filling equipment (watering can filling) is not permitted .
Failure to observe these instructions may result in component or engine damage.
The filling specification must be observed.
It is essential to visually check the vacuum filling equipment before use to check that it is functioning correctly and clean.
It is not permissible to operate the vehicle if the filling procedure has not been fully completed. Otherwise there may be functional limitations (degradation) or overheating.
A bleeding procedure is required after a part has been exchanged in the cooling system and/or after refilling the cooling system.

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

NOTE: TECHNICAL INFORMATION
When the engine is stopped after the completion of trip, it may be necessary to run the electric fan. In rare cases, operation of the electric fan can take up to 11 minutes. This protects the components. In this case, replacing the electric fan is not necessary.

Preliminary work

Refer to REMOVING THE TOP RIGHT AND LEFT COVER IN THE ENGINE COMPARTMENT .
Refer to REMOVING UPPER CROSS CONNECTION .
Refer to REMOVING THE TENSION STRUT AT THE SHOCK TOWER ON THE LEFT AND RIGHT .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING BOTH INTAKE FILTER HOUSINGS .
Refer to REMOVING THE RIGHT INTAKE SILENCER BRACKET .
Refer to REMOVING THE LEFT INTAKE SILENCER BRACKET .
Refer to REMOVING THE UNFILTERED-AIR DUCT ON THE RIGHT AND LEFT .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE FAN COWL .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
Refer to DRAINING THE COOLANT FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to REMOVING THE LEFT AND RIGHT UNDERSHIELD (TANK COVER) .
Refer to REMOVING THE REAR LEFT AND RIGHT TENSION STRUT .
Refer to REMOVING THE LEFT AND RIGHT REAR DIFFUSER .
Refer to REMOVING EXHAUST SYSTEM .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
Refer to REMOVING THE LEFT LAMBDA OXYGEN SENSOR .
Refer to REMOVING THE LEFT INTAKE SILENCER BRACKET .
Refer to REMOVING UPPER HEAT SHIELD .
Refer to REMOVING THE RIGHT OXYGEN SENSOR MONITOR .
Refer to REMOVING THE CATALYTIC CONVERTER FOR CYLINDERS 5 THROUGH 8 .
Refer to REMOVING THE CARRIER PLATE .
Refer to PARTIALLY RELEASING THE RIGHT CHARGE AIR LINE .
Refer to REMOVING ENGINE VENT LINE OF CYLINDERS 1 TO 4 .
Refer to REMOVING THE INTAKE PIPE THE ENGINE VENTILATION LINE .
Refer to REMOVING THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 1 TO 4 .
Refer to RELEASING LEFT CHARGE AIR LINE PARTIALLY .
Refer to PARTIALLY RELEASING THE RIGHT CHARGE AIR LINE .
Refer to REMOVING RIGHT CLEAN AIR PIPE .
Refer to REMOVING LEFT CLEAN AIR PIPE .
Refer to REMOVING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to REMOVING THE IGNITION COIL ON CYLINDER 5 .
Refer to REMOVING IGNITION COIL OF CYLINDER BANK 1 .
Refer to REMOVING DRIVE BELT .
Refer to REMOVING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
Refer to REMOVING THE OIL FILLER CAP .
Refer to REMOVING LEFT CHARGE AIR COOLER .
Refer to REMOVING RIGHT CHARGE AIR COOLER .
Refer to REMOVING GUIDE TUBE FOR OIL DIPSTICK .
Refer to REMOVING RIGHT RAIL .
Refer to REMOVING FUEL DELIVERY LINE .
Refer to REMOVING RIGHT HIGH-PRESSURE PUMP .
Refer to PARTIALLY RELEASING THE WIRING HARNESS SECTION OF THE RIGHT CYLINDER HEAD COVER .
Refer to REMOVING THE INJECTORS FOR CYLINDERS 1 TO 4 .
Refer to REMOVING VANOS SOLENOID ACTUATOR, EXHAUST OF CYLINDER BANK 1 .
Refer to REMOVING THE VANOS SOLENOID ACTUATOR INTAKE OF CYLINDER BANK 1 .
Refer to REMOVING RIGHT CYLINDER HEAD COVER .
Refer to REMOVING THE SEALING CAP ON THE CYLINDER HEAD OF THE CYLINDER BANK 1 .
Refer to MOVING THE CRANKSHAFT TO THE INSTALLATION POSITION TO ADJUST THE TIMINGS .
Refer to CHECKING THE VANOS ADJUSTER OF CYLINDER BANK 1 .
Refer to RELAXING CHAIN TENSIONER ON BANK 1 FOR CHECKING OR SETTING TIMING .
Refer to REMOVING HYDRAULIC CHAIN TENSIONER OF CYLINDER BANK 1 .
Refer to PRELOADING THE TIMING CHAIN OF CYLINDER BANK 1 .
Refer to FIXING THE ENGINE IN THE INSTALLATION POSITION ON CYLINDER 1 (SET VALVE TIMINGS) .
Refer to REMOVING BOTH RIGHT VANOS ADJUSTERS .
Refer to REMOVING SPECIAL TOOL FOR FIXING CAMSHAFTS ON BANK 1 .
Refer to REMOVING THE SPECIAL TOOL TO PRETENSION THE TIMING CHAIN AT CYLINDER BANK 1 .

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.

Prepare the special tool 0 494 116 (11 8 352) from the set of special tools 0 493 997 (11 8 350) in a vice.
Using a tape measure in area (A) mark out 22 mm.
Using a tape measure in area (B) mark out 10 mm.
Set a punch in the center of the marked area (1) .
Drill a hole with a 6.5 mm drill bit.

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NOTE: TECHNICAL INFORMATION
Work must be carried out carefully in order to avoid component damage.

Position special tool 0 494 116 (11 8 352) (2) from the special tool set 0 493 997 (11 8 350) so that it is supported by the cylinder head in area (3) .
Secure special tool 0 494 116 (11 8 352) (2) from the special tool set 0 493 997 (11 8 350) to the cylinder head with a M6x15 screw (1) .

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TIGHTENING TORQUE SPECIFICATIONS

Special tool to cylinder head 1 to 4
M6x15	tightening torque	10 Nm

Attach the special tool 0 490 567 (11 0 020) on the hoisting eye and on the special tool 0 494 116 (11 8 352) from the special tool set 0 493 997 (11 8 350) .
Remove the positive battery cable (1) from the clamp (arrow).
Unlock plug connection (2) and disconnect.
Release the connector (3) with the clamp (arrow).
Release the wiring harness section (4) from the clamp (arrow).

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Unlock the connector (1) and detach from pressure sensor on intake plenum.
Unlock the connector (2) and detach from the servomotor.

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Loosen screws (1) .
Remove the heat shield (2) at rear on the cylinder head.

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Twist the intake camshaft (1) by 180° in the direction of the arrow using a open-end wrench (2) .
This consequently guarantees accessibility to the cylinder head bolts.

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Release the screws (1) the timing case cover.

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Release the screw of the slide rail on the cylinder head of cylinder bank (1) .

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Loosen screws (1) to (10) .

Fig 1: Right Cylinder Head Screws Loosening Sequence

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NOTE: TECHNICAL INFORMATION
Work must be carried out carefully in order to avoid component damage.

Attach the special tool 0 490 561 (11 0 000) on the retaining tab (1) and on the special tool 0 494 116 (11 8 352) from the set of special tools 0 493 997 (11 8 350) .

NOTE: TECHNICAL INFORMATION
Work must be carried out carefully in order to avoid component damage.

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Mind the free movement of the tensioning rails and slide rails .
Risk of breakage!
Carefully lift the cylinder head using a workshop crane.
Carefully feed out and remove the cylinder head with a workshop crane and three support persons.
Remove cylinder head gasket (1) .

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