Removing the cylinder head
DANGER
High-voltage system.
The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock!
- All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
- For additional information see: 61 00... SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS .
- For additional information see: 61 25... NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT .
WARNING:
Hot surfaces.
Risk of burning!
Risk of burning!
- Perform all work only on components that have cooled down.
WARNING:
Working on fuel system.
Risk of fire! Danger of explosion!
Risk of fire! Danger of explosion!
- When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
- Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
- No fire, sparks, open flames or smoking.
CAUTION:
On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!
Injury hazard!
- Wear suitable personal protective equipment.
- Before performing any installation work, allow cooling system to cool down to less than 40°C.
- Note warnings on cylinder head cover.
NOTE:
RISK OF DAMAGE
Engine damage due to missing motor oil.
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train.
Engine damage due to missing motor oil.
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train.
- After replacing the cylinder head or the engine, do not start the engine without observing the repair notes.
- It is imperative you observe the repair notes for cylinder head or engine replacement.
- For additional information, see: REPAIR NOTES FOR CYLINDER HEAD OR ENGINE REPLACEMENT .
NOTE:
TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Preliminary work
- Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
- Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
- Refer to REMOVING THE ACOUSTIC COVER .
- Refer to REMOVING THE SEAL FOR THE HOOD REAR .
- Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT .
- Refer to REMOVING THE COVER OF THE REAR RIGHT ENGINE COMPARTMENT .
- Refer to REMOVING LEFT AND RIGHT WIPER ARM .
- Refer to REMOVING THE COWL COVER .
- Refer to REMOVING TRAILING LINK AT SPRING BOLT .
- Refer to REMOVING THE CENTER COWL UPPER PART .
- Refer to RELEASING THE HIGH-VOLTAGE CABLES ON THE EME .
- Refer to REMOVING ACOUSTIC COVER AT REAR .
- Refer to REMOVING BOTH ACTUATORS .
- Refer to REMOVING ALL IGNITION COILS .
- Refer to REMOVING ALL SPARK PLUGS .
- Refer to REMOVING FUEL DELIVERY LINE .
- Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
- Refer to REMOVING HIGH PRESSURE PUMP .
- Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 1 TO 3 .
- Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 4 TO 6 .
- Refer to REMOVING THE CYLINDER HEAD COVER .
- Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
- Refer to REMOVING BOTH FRONT-END STRUTS .
- Refer to REMOVING FRONT CROSS CONNECTION (FRONT-END STRUT REMOVED) .
- Refer to REMOVING THE REAR TOP CROSS CONNECTION .
- Refer to REMOVING FAN COWL .
- Refer to REMOVING THE INTAKE FILTER HOUSING (TENSION STRUT ON SHOCK TOWER REMOVED) .
- Refer to REMOVING THE RESONATOR WITH THE TOP CLEAN AIR PIPE .
- Refer to REMOVING BOTTOM CLEAN AIR PIPE .
- Refer to REMOVING CHARGE AIR LINE .
- Refer to REMOVING THE DRIVE BELT FOR COOLANT PUMP .
- Refer to REMOVING THE HOLDER OF THE POSITIVE BATTERY CABLE .
- Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
- Refer to REMOVING THE OXYGEN SENSOR MONITOR .
- Refer to REMOVING THE DME CONTROL UNIT .
- Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
- Refer to REMOVING CONTROL UNIT BRACKET .
- Refer to REMOVING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
- Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR AND THRUST FIELD RESPECTIVELY .
- Refer to REMOVING REAR UNDERBODY PROTECTION .
- Refer to REMOVING THE FRONT THRUST FIELD .
- Refer to REMOVING THE STIFFENING PLATE .
- Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY .
- Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
- Refer to IF INSTALLED: REMOVING THE TORSION STRUT ON THE RIGHT AND LEFT WHERE REQUIRED .
- Refer to REMOVING THE REAR AXLE COVER .
- Refer to REMOVING THE REAR DIFFUSER .
- Refer to REMOVING COMPLETE EXHAUST SYSTEM .
- Refer to REMOVING CATALYTIC CONVERTER .
- Refer to REMOVING THE OIL RETURN LINE FOR THE TURBOCHARGER .
- Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
- Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to CONNECTING THE COOLANT LINE OF HIGH-TEMPERATURE COOLANT CIRCUIT .
- Refer to CONNECTING THE COOLANT LINE OF LOW-TEMPERATURE COOLANT CIRCUIT .
- Refer to REMOVING TANK VENT VALVE .
- Refer to REMOVING THE INTAKE PLENUM .
- Refer to REMOVING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
- Refer to REMOVING THE THERMOSTAT FROM THE TRANSMISSION OIL LINES .
- Refer to PARTIALLY RELEASING OIL SUMP ACOUSTIC COVER .
- Refer to BLOCKING ENGINE IN TDC FIRING POSITION .
- Refer to REMOVING CHAIN TENSIONER .
- Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING INTAKE ADJUSTER .
- Refer to REMOVING EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING THE TEST GAUGES FOR SECURING THE CAMSHAFTS .
CAUTION:
Heavy component.
Heavy components can lead to injury or damage.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
NOTE:
TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
- Prepare special tool 0 495 747 (11 8 580)
.
- Prepare special tool 0 490 567 (11 0 020) .
- Prepare the workshop crane 2 220 718
.
- Unlock plug connection (1)
and disconnect.
- Unlock and loosen coolant line (1) .
- Catch and dispose of leakage coolant.
- Unlock plug connection (2) and disconnect.
- Loosen clamps (3) .
- Guide out the wiring harness section (4) for the sensor system 1 and set side.
- Loosen screw (1)
.
- Position special tool 2 470 546
on the screw (1)
.
- Release the screw (1) using the special tool 2 470 546 .
- Feed out the screw (1)
using special tool 2 470 546
and remove.
- Feed out the coolant return line (2) for the turbocharger and set it aside.
- Feed out the oil feed line (1)
for the turbocharger and set it aside.
- Loosen screws (1) and (2) .
- Feed the coolant feed line for the turbocharger (3) out of the crankcase and place aside.
- Catch and dispose of leakage coolant.
- Loosen screws (1) and (2) .
- Feed out the support (3)
and remove it.
- Unlock plug connection (1)
and disconnect.
- Unlock and release the clamps (1) and (2) .
- Thread out positive battery cable (3) and set it aside.
- Loosen screws (1) .
- Feed out the transmission wiring harness (2)
on the wiring harness section (3)
for sensor system 1 and place to one side.
- Loosen screw (1) .
- Feed out the wiring harness section (2) for sensor system 1 and place to one side.
NOTE:
The figure shows the rear of the engine.
- Loosen screw (1) .
- Guide out and remove the cover (2) .
- Loosen screws (1) .
- Guide out and remove slide rail (2)
.
- Unscrew the bearing journal (1)
from the guide rail (2)
.
- Rotate intake camshaft, if necessary in the position shown.
The recess (2) must point up.
- Loosen screw (1) .
- Shift the camshaft sensor wheel (1)
in direction of cylinder 1 and feed out from the intake camshaft.
- Insert and position the special tool 2 459 012 at the cylinder head.
- Tighten the screws (1) of the special tool 2 459 012 .
TIGHTENING TORQUE SPECIFICATIONS
| Special tool to cylinder head | ||
| M8 | tightening torque | 21.5 Nm |
- Loosen the cylinder head bolts in the sequence from (5) to (1) .
- Loosen the cylinder head bolts with the special tool 0 495 747 (11 8 580).
- Undo the screws using the special tool 0 495 747 (118 580) in the order (14) to (1).
- Feed out and remove all the cylinder head bolts (1) .
- Feed out and remove all the washers (2) .
CAUTION:
Heavy component.
Heavy components can lead to injury or damage.
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.
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.
- Attach special tool 0 490 567 (11 0 020) to workshop crane.
- Lift out the cylinder head (1) and the turbocharger with the help of a second person, using the workshop crane and the special tool 0 490 567 (11 0 020) .