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.

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With the help of a support person, the special tool 2 220 718 and the special tool 0 490 567 (11 0 020) , feed in, position and install the cylinder head (1) and the exhaust turbocharger.
Ensure that the guide rails of the timing chain are not damaged.
Feed in and install all the washers (2) .
Replace all 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 present in the threaded holes of the engine block.
Insert and install the 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.

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 0 495 747 (11 8 580) and 0 490 504 (00 9 120) in the sequence (1) to (10) .

Fig 1: Cylinder Head Bolts Tightening Sequence

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TIGHTENING TORQUES SPECIFICATION

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 screws (1) to (5) .
Parts: Screws
Make sure that there is no coolant, water or engine oil in the threaded holes of the timing case cover.
Screw in screws (1) up to (5) .

Tighten screws in the sequence (1) to (5) .

TIGHTENING TORQUES SPECIFICATION

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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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 TORQUES SPECIFICATION

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 TORQUES SPECIFICATION

Sliding rail to cylinder head
M6x16	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 TORQUES SPECIFICATION

Cable bracket on rear cylinder head/transmission
M6 x 20	Tightening torque	10 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.

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Guide in and install the transmission wiring harness (2) on the wiring harness section (3) for sensor system 1.

Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATION

Cable bracket on rear cylinder head/transmission
M6 x 20	Tightening torque	10 Nm

Guide in and install cover (2) .

Tighten down screw (1) .

TIGHTENING TORQUES SPECIFICATION

Cover to rear cylinder head
M6	Tightening torque	8 Nm

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Connect and lock connector (3) on the coolant temperature sensor.
Ensure that the connector (3) audibly engages on the coolant temperature sensor.
Connect and lock connector (2) on the knock sensor.
Ensure that the connector (2) audibly engages on the knock sensor.
Connect and lock coolant line (1) .
Make sure that the coolant line (1) engages audibly.

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Feed in the camshaft sensor wheel (4) on the guide pin (5) and position.
Fasten the intake camshaft (2) with a standard open-end wrench (1) .

Tighten down screw (3) .

TIGHTENING TORQUES SPECIFICATION

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

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Connect connectors (1) and lock.
Make sure the connector (1) engages audibly.

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Insert and install the holder (2) .

Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATION

Manifold bracket for intake air at cylinder head
M6X16	Tightening torque	8 Nm

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Insert and position the holders (3) .

Tighten down screws (1) and (2) .

TIGHTENING TORQUES SPECIFICATION

Holder for electrical auxiliary coolant pump to cylinder head
M6	Tightening torque	7 Nm

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Thread in ground cable (2) and install.

Tighten nut (1) .

TIGHTENING TORQUES SPECIFICATION

Standard screw connection M6
M6	Tightening torque	8 Nm

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Replace the sealing ring of the oil feed line (1) with the special tool 0 496 714 (00 9 030) .
Parts: Sealing ring
Feed in and install the oil feed line (1) in arrow direction on the exhaust turbocharger (2) .

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Tighten the screw (1) on the oil feed line (2) .

TIGHTENING TORQUES SPECIFICATION

Oil feed line to exhaust turbocharger/crankcase
M6x12	Tightening torque	8 Nm

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Connect connectors (1) and lock.
Make sure the connector (1) engages audibly.

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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 INSTALLING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
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 THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING THE COOLANT RETURNING LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING THE COOLANT FEED LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING CATALYTIC CONVERTER .
Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
Refer to INSTALLING THE RIGHT REAR TORSION STRUT .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to INSTALLING BOTH ACTUATORS .
Refer to PREPARING THE INJECTORS FOR INSTALLATION .
Refer to INSTALLING THE RAIL WITH INJECTORS .
Refer to INSTALLING HIGH PRESSURE PUMP .
Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
Refer to INSTALLING FUEL DELIVERY LINE .
Refer to INSTALLING ALL SPARK PLUGS .
Refer to INSTALLING ALL IGNITION COILS .
Refer to INSTALLING LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE CYLINDER HEAD COVER ACOUSTIC COVER .
Refer to INSTALLING THE HEAT SHIELD ON THE CYLINDER HEAD .
Refer to INSTALLING THE ACOUSTIC COVER FOR THE ENGINE, FRONT .
Refer to INSTALLING CHARGE AIR LINE .
Refer to INSTALLING THE CLEAN AIR PIPE WITH THE RESONATOR .
Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
Refer to ACTIVATING VEHICLE ELECTRICAL SYSTEM .
Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to CHECKING THE HIGH-TEMPERATURE COOLING SYSTEM FOR WATERTIGHTNESS .
Refer to CHECKING LOW-TEMPERATURE COOLING SYSTEM FOR WATERTIGHTNESS .
Refer to CHECKING ENGINE OIL LEVEL .
Refer to INSTALLING CENTER FIREWALL LOWER PART .
Refer to INSTALLING ACOUSTIC COVER AT REAR .
Refer to INSTALLING THE CENTER COWL UPPER PART .
Refer to INSTALLING THRUST FIELD ON THE 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 REAR HOOD SEAL .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING BOTTOM FRONT COVER FROM THE SIDE .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to TAKING HOOD OUT OF THE SERVICE POSITION .