Installing the right cylinder head

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CAUTION: Heavy component .
Heavy components can lead to injury or damage .

Remove and install heavy components with the aid of another person/other persons.

CAUTION: Swirling dirt particles caused by compressed air .
Injury hazard!

Collect dirt particles, e.g. when blowing out, use cloth to do so.
Wear safety goggles.

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.

NOTE: RISK OF DAMAGE
Damage to the surface .
The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage .

Do not use any metal-cutting tools.

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.

Check if there are fluids or foreign materials present in the cylinder bores (1); remove fluids or foreign materials where required.

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Check the fitting sleeves (1) for correct seating and damage and 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 the 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 the 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 bores of cylinder head bolts (1) with compressed air.

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Clean sealing surface (1) with special tool 0 495 103 (11 4 471) from the 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 the 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: screw
Position cylinder head gasket (1) on the fitting sleeves on the engine block.
If the cylinder head was reworked, then a thicker cylinder head gasket is to be installed .

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NOTE: TECHNICAL INFORMATION
The work must be performed with vehicle care to prevent 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).
Position cylinder head with a workshop crane.

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NOTE: TECHNICAL INFORMATION
The work must be performed with vehicle care to prevent component damage.
Insert and install the cylinder head with a workshop crane and 3 support persons carefully.
When feeding in and installing the cylinder head (1), make sure that the slide rails and timing chain (2) are not damaged.
Detach the special tool 0 490 567 (11 0 020) 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).

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Tightening right cylinder head

Tightening the right cylinder head

Fig 1: Cylinder Head Screws Tightening Sequence

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

TIGHTENING TORQUE SPECIFICATIONS

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

Detach the special tool 0 490 567 (11 0 020) on the engine mounting bracket and on the special tool 0 494 116 (11 8 352) from the set of special tools 0 493 997 (11 8 350).
Loosen screw (1).
Remove the special tool 0 494 116 (11 8 352) from the set of special tools 0 493 997 (11 8 350) (2) from the support (3).

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

TIGHTENING TORQUE SPECIFICATIONS

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

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Replace sealing ring (1).
Parts: Sealing ring
Position sealing ring (1) on the bearing screw (2).

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Position the slide rail.

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

TIGHTENING TORQUE SPECIFICATIONS

Slide rail to cylinder head
Bearing screw	Tightening torque	25 Nm

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Fasten the wiring harness section (4) at the clamp (arrowed).
Fasten the plug connector (3) using the clamp (arrowed).
Connect connectors (2) and lock.
The connector (2) must engage audibly.
Secure the positive battery cable (1) at the clamp (arrowed).

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Connect the connector (1) to the pressure sensor on the intake plenum and lock audibly.
Connect the connector (2) to the servomotor and lock audibly.

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Install the heat shield (2) on the rear of the cylinder head.
Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Heat protection plate
M6x16	tightening torque	10 Nm

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Follow-up work

Refer to INSTALLING BOTH RIGHT VANOS ADJUSTERS .
Refer to REMOVING THE SPECIAL TOOL TO PRETENSION THE TIMING CHAIN AT CYLINDER BANK 1 .
Refer to INSTALLING THE HYDRAULIC CHAIN TENSIONER OF CYLINDER BANK 1 .
Refer to INSTALLING THE SEALING CAP ON THE CYLINDER HEAD OF CYLINDER BANK 1 .
Refer to INSTALLING THE CYLINDER HEAD COVER ON THE RIGHT .
Refer to INSTALLING VANOS SOLENOID ACTUATOR, EXHAUST OF CYLINDER BANK 1 .
Refer to INSTALLING THE VANOS SOLENOID ACTUATOR INTAKE OF CYLINDER BANK 1 .
Refer to INSTALLING THE INJECTORS FOR THE CYLINDERS 1 TO 4 .
Refer to SECURING THE WIRING HARNESS SECTION OF THE CYLINDER HEAD COVER ON THE RIGHT .
Refer to INSTALLING RIGHT HIGH PRESSURE PUMP .
Refer to INSTALLING FUEL DELIVERY LINE .
Refer to INSTALLING THE RIGHT HIGH-PRESSURE RAIL .
Refer to INSTALLING GUIDE TUBE FOR OIL DIPSTICK .
Refer to INSTALLING THE RIGHT-HAND CHARGE AIR COOLER .
Refer to INSTALLING THE LEFT-HAND CHARGE AIR COOLER .
Refer to INSTALLING THE OIL FILLER CAP .
Refer to INSTALLING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
Refer to INSTALLING DRIVE BELT .
Refer to INSTALLING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to INSTALLING IGNITION COIL ON CYLINDER 1 .
Refer to INSTALLING IGNITION COILS FROM CYLINDER BANK 1 .
Refer to INSTALLING LEFT CLEAN AIR PIPE .
Refer to INSTALLING RIGHT CLEAN AIR PIPE .
Refer to CONNECTING THE RIGHT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
Refer to CONNECTING THE LEFT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
Refer to INSTALLING THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 1 TO 4 .
Refer to INSTALLING THE INTAKE PIPE OF THE ENGINE VENTILATION LINE .
Refer to INSTALLING THE ENGINE VENTILATION LINE OF CYLINDERS 1 TO 4 .
Refer to CONNECTING THE RIGHT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
Refer to INSTALLING THE CARRIER PLATE .
Refer to INSTALLING THE CATALYTIC CONVERTER OF CYLINDERS 5 TO 8 .
Refer to INSTALLING THE RIGHT OXYGEN SENSOR MONITOR .
Refer to INSTALLING HEAT SHIELD, TOP .
Refer to INSTALLING THE LEFT INTAKE SILENCER BRACKET .
Refer to INSTALLING THE LEFT LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE RIGHT LAMBDA OXYGEN SENSOR .
Refer to INSTALLING EXHAUST SYSTEM .
Refer to INSTALLING THE LEFT AND RIGHT REAR DIFFUSER .
Refer to INSTALLING THE REAR LEFT AND RIGHT TENSION STRUT .
Refer to INSTALLING THE LEFT AND RIGHT UNDERSHIELD (TANK COVER) .
Refer to CONNECTING THE COOLANT HOSE TO THE AUXILIARY COOLANT PUMP .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to INSTALLING FAN COWL .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING THE RIGHT AND LEFT UNFILTERED-AIR DUCT .
Refer to INSTALLING THE LEFT INTAKE SILENCER BRACKET .
Refer to INSTALLING THE RIGHT INTAKE SILENCER BRACKET .
Refer to INSTALLING BOTH INTAKE FILTER HOUSING .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING TENSION STRUT ON LEFT AND RIGHT SHOCK TOWER .
Refer to INSTALLING UPPER CROSS CONNECTION .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT , and INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE TOP RIGHT .