Removing the cylinder head

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WARNING: Hot surfaces .
Risk of burning!

Perform all work only on components that have cooled down.

WARNING: Working on 12 V electrical system .
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment.
Detach battery ground lead from battery.
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.

WARNING: Working on fuel system .
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!

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 .

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: RISK OF DAMAGE
Damage to battery terminal, the safety battery terminal or the intelligent battery sensor (IBS) .
Damaged battery terminals can lead to malfunctions or vehicle electrical system faults .

Detach battery terminal from battery pole by carefully shifting to and fro. Do not pry off using a tool.

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

Preliminary work

Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
Refer to REMOVING THE SEAL FOR THE HOOD REAR .
Refer to REMOVING THE ACOUSTIC COVER .
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 WINDSHIELD PANEL COVER .
Refer to REMOVING THE CENTER COWL UPPER PART .
Refer to REMOVING ACOUSTIC COVER AT REAR .
Refer to REMOVING THE CENTER BULKHEAD LOWER PART .
Refer to REMOVING SEAL FOR FRONT HOOD .
Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
Refer to IF INSTALLED: PARTIALLY REMOVING THE TOP RIGHT AND LEFT COVER IN THE ENGINE COMPARTMENT .
Refer to REMOVING UPPER CROSS CONNECTION .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE FAN COWL .
Refer to REMOVING INTAKE SILENCER HOUSING .
Refer to REMOVING ENGINE VENTILATION LINE .
Refer to REMOVING CLEAN AIR PIPE .
Refer to REMOVING CHARGE AIR LINE .
Refer to REMOVING THE ADAPTER FOR ENGINE VENTILATION LINE WITH HEATING ELEMENT ON EXHAUST TURBOCHARGER .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
Refer to REMOVING THE OXYGEN SENSOR MONITOR .
Refer to REMOVING ALL IGNITION COILS .
Refer to REMOVING ALL SPARK PLUGS .
Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
Refer to REMOVING FUEL DELIVERY LINE .
Refer to REMOVING HIGH PRESSURE PUMP .
Refer to REMOVING THE RAIL WITH INJECTORS OF CYLINDERS 1 TO 3 .
Refer to REMOVING THE RAIL WITH INJECTORS OF CYLINDERS 4 TO 6 .
Refer to REMOVING BOTH ACTUATORS .
Refer to REMOVING THE CYLINDER HEAD COVER .
Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
Refer to REMOVING THE DME CONTROL UNIT .
Refer to REMOVING CONTROL UNIT BRACKET .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR .
Refer to IF INSTALLED: REMOVE THE UNDERBODY PROTECTION OF THE STEERING SYSTEM .
Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY .
Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to REMOVING COMPLETE EXHAUST SYSTEM .
Refer to REMOVING CATALYTIC CONVERTER .
Refer to REMOVING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to IF INSTALLED: PARTIALLY RELEASE THE ENGINE OIL COOLER .
Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to CONNECTING THE COOLANT LINES FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
Refer to CONNECTING THE COOLANT LINE TO THE HIGH-TEMPERATURE COOLANT RADIATOR .
Refer to REMOVING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
Refer to REMOVING TANK VENT VALVE .
Refer to REMOVING THE INTAKE PLENUM .
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 .

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.

Prepare special tool 0 495 747 (11 8 580) .

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Prepare special tool 0 490 567 (11 0 020) .

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Prepare the special tool 2 220 718 .

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Unlock plug connection (1) and disconnect.

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Unlock and loosen coolant line (1) .
Catch and dispose of escaping coolant.
Unlock plug connection (2) and disconnect.
Loosen clamps (3) .
Guide out the wiring harness section (4) for the sensor system 1 and set it aside.

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Unlock and detach the coolant return line (1) on the coolant pump (2) for the exhaust turbocharger.
Catch and dispose of escaping coolant.

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Loosen screws (1) .
Loosen screw (2) .
Feed out and remove the heat shield (3) .

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Loosen screws (1) .
Feed out and remove the heat shield (2) .

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Release the screw (1) at the coolant return line (2) .

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Loosen screw (1) .
Guide out the oil feed line (2) for the exhaust turbocharger and set it aside.
Catch and dispose of emerging engine oil.

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Loosen screws (1) and (2) .
Guide the coolant feed line for the exhaust turbocharger (3) out of the crankcase and set it aside.
Catch and dispose of escaping coolant.

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Loosen screws (1) and (2) .
Feed out the support (3) and remove it.

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Unlock and release the clamps (1) and (2) .
Thread out positive battery cable (3) and set it aside.

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Loosen screws (1) .
Feed out the transmission wiring harness (2) on the wiring harness section (3) for the sensor system 1 and set aside.

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Loosen screw (1) .
Feed out the wiring harness section (2) for the sensor system 1 and set it aside.

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NOTE: The figure shows the rear of the engine.
Loosen screw (1) .
Guide out and remove the cover (2) .

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Loosen screws (1) .
Guide out and remove slide rail (2) .

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Unscrew the bearing journal (1) from the guide rail (2) .

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Rotate the intake camshaft, if necessary, in the position shown.
The recess (2) must point upward.
Loosen screw (1) .

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Slide the camshaft sensor wheel (1) in the direction of cylinder 1 and guide it out of the intake camshaft.

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Insert and position the special tool 2 459 012 at the cylinder head.

Tighten the screws (1) of special tool 2 459 012 .

TIGHTENING TORQUE SPECIFICATION

Special tool to cylinder head
M8	Tightening torque	21.5 Nm

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

Fig 1: Cylinder Head Bolts Loosening Sequence
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Loosen the cylinder head bolts with the special tool 0 495 747 (11 8 580) .

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Loosen the screws using special tool 0 495 747 (11 8 580) in the order (14) to (1) .

Fig 2: Cylinder Head Screws Loosening Sequence
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Feed out and remove all the cylinder head bolts (1) .
Feed out and remove all the washers (2) .

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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.
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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Attach special tool 0 490 567 (11 0 020) to workshop crane.
Lift out the cylinder head (1) and the exhaust turbocharger with the help of a second person, using the workshop crane and the special tool 0 490 567 (11 0 020) .