Installing the left cylinder head

• There must be no fluids or foreign materials in the cylinder bores, remove if necessary.

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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 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 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 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 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:  Screws

• Position cylinder head gasket (1) on the fitting sleeves on the engine block.

  If the cylinder head has been reworked, a thicker cylinder head gasket must be installed. 

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

Tightening left cylinder head 

Tightening the left cylinder head 

Fig 1: Left Cylinder Head Screws Tightening Sequence

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

• Detach the special tool 0 490 567 (11 0 020) on the engine mounting bracket (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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• Release the screws (1) on the special tool  0 494 116 (11 8 352)  from the set of special tools 0 493 997 (11 8 350) from the cylinder head. 
• Remove 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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  Fastening cylinder head bolts on timing case cover 

  • 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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  Mounting the special tool on the processed surface of the camshaft 

  • Pay attention to the installation position:

    For the camshaft (1) there are three machined surface. The special tool 2 249 117 can only be mounted in the marked position, (arrow).

  • Mount special tool 2 249 117 .

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  • Replace sealing ring (1).
  • Position sealing ring (1) on the bearing bolt (2).

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  • Position the slide rail.
  • Tighten the screw of the slide rail on the cylinder head of cylinder bank (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Slide rail to cylinder head
  Bearing screw	Tightening torque	25 Nm

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  Install both exhaust manifolds 

  NOTE: TECHNICAL INFORMATION 
  The sealing surfaces must be free of oil, grease and cleaning agents.
  NOTE: TECHNICAL INFORMATION 
  Make sure that there are no particles or impurities in the medium openings.
  Coolant or foreign substances in the oil can cause engine damage such as damage to the connecting rod bearing.
  NOTE: RISK OF DAMAGE 
  Careless handling of tools and sharp edged components. 
  Scratches, surface damage. 

  • Protect working area.
  • Handle tools and components carefully.

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• Clean sealing surfaces (1).
  NOTE: TECHNICAL INFORMATION 
  The sealing surfaces must be free of oil, grease and cleaning agents.
  NOTE: TECHNICAL INFORMATION 
  Make sure that there are no particles or impurities in the medium openings. Coolant or foreign substances in the oil can cause engine damage such as damage to the connecting rod bearing.

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

  • Protect working area.
  • Handle tools and components carefully.
• Clean sealing surfaces (1).
• Replace seals (1).

  Parts:  Seals

• Position seals (1).

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  NOTE: TECHNICAL INFORMATION 
  The seals fit in one installation orientation only. Ensure correct installation.
• Install seal (1) with the side of the bead (2) (seal cavity) toward the exhaust manifold (3).

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• Position exhaust manifold (2).
• Replace screws (1).

  Parts:  Screws

• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Exhaust manifold
  M8x40 screw Replace screw.	tightening torque	25 Nm
  	Angle of rotation	45°

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• Position exhaust manifold (2).
• Replace screws (1).

  Parts:  Screws

• Tighten down screws (1).

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• Slide the coolant hose on.
• Tighten the hose clamp (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Coolant ventilation line
  Hose clamp	Tightening torque	1.5 Nm

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  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Secure the wiring harness mountings (1) below the intake system.

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Follow-up work 

• Refer to INSTALLING BOTH LEFT VANOS ADJUSTERS (CYLINDER HEAD INSTALLATION CYLINDER BANK 2) .
• Refer to INSTALLING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
• Refer to INSTALLING THE LEFT CYLINDER HEAD COVER .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING HEAT SHIELD ON THE BOTTOM .
• Refer to INSTALLING FRONT HEAT SHIELD .
• Refer to INSTALLING BOTH EXHAUST MANIFOLDS .
• Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 1 TO 4 .
• Refer to INSTALLING LEFT AND RIGHT EXHAUST TURBOCHARGERS .
• Refer to MOUNTING FIXTURE ON THE RIGHT .
• Refer to INSTALLING LEFT MOUNT .
• Refer to INSTALLING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to INSTALLING CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to INSTALLING CATALYTIC CONVERTER NEAR THE ENGINE ABOVE CYLINDER BANK 1 .
• Refer to INSTALLING UPPER CATALYTIC CONVERTER NEAR ENGINE FOR BANK 2 .
• Installing holder with the wiring harness for the sensor system of cylinder bank 2.

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  • Position the holder with the wiring harness for the sensor system.
  • Tighten screws (2).
    TIGHTENING TORQUES
    
    

    Holder of sensor system
    M6x16 screw	Tightening torque	10Nm

  • Connect plug connection (3) and lock.
  • Engage the coolant ventilation line in area (1) at the holder.
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE LEFT THROTTLE BODY .
• Refer to INSTALLING THE INTAKE PIPE .
• Refer to INSTALLING THE LEFT-HAND CHARGE AIR COOLER .
• Refer to INSTALLING THE RIGHT-HAND CHARGE AIR COOLER .
• Refer to INSTALLING OIL FILLER NECK .
• Refer to CLOSING THE COOLANT PUMPS .
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to INSTALLING COOLANT PUMPS .
• Refer to INSTALLING THE BELT TENSIONER .
• Refer to INSTALLING ALTERNATOR .
• Refer to INSTALLING DRIVE BELT .
• Refer to INSTALLING FAN COWL WITH ELECTRIC MOTOR .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to INSTALLING CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to INSTALLING RIGHT INTAKE SILENCER HOUSING .
• Refer to INSTALLING LEFT INTAKE SILENCER HOUSING .
• Refer to INSTALLING FRONT CROSS CONNECTION .
• Refer to TIGHTENING THE LEFT FRONT-END STRUT .
• Refer to TIGHTENING THE FRONT-END STRUT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
• Refer to INSTALLING HEAT SHIELD, TOP .
• Installing conduit on bank 2.

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  • Clip the wiring harness (2) into the clamps (1).

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  • Position the wiring harness.
  • Tighten down screws (1).
    TIGHTENING TORQUES
    
    

    Cable duct
    M6x16 screw	Tightening torque	10Nm

• Refer to INSTALLING ENGINE VENTILATION LINE OF CYLINDER BANK 1 .
• Refer to INSTALLING THE TANK VENTILATION LINE OF CYLINDER BANK 1 PARTIALLY .
• Installing cable duct at cylinder bank 1.

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  • Position the conduit (2).
  • Tighten the screws (1).
  TIGHTENING TORQUES
  
  

  Cable duct
  M6x16 screw	Tightening torque	10Nm

• Refer to INSTALLING THE ENGINE VENTILATION LINE OF CYLINDER BANK 2 .
• Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
• Refer to CHECKING THE POSITION OF THE HEAT SHIELD .
• Refer to INSTALLING THE EXPANSION TANK FOR THE CHARGE AIR COOLER .
• Refer to INSTALLING COOLANT EXPANSION TANK .
• Refer to INSTALLING HOLDER OF THE DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
• Refer to INSTALLING THE LEFT HIGH PRESSURE PUMP .
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE CENTER COWL UPPER PART .
• Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Installing the rear right engine compartment cover.

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  Remove the battery cover  .

  NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
  • Remove the special tool 2 452 007  from the battery.

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  • Install the cover (2).
  • Lock the lock (1).
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to INSTALLING INJECTORS .
• Refer to CONNECTING THE CONNECTOR OF THE INJECTORS OF CYLINDER BANK 2 .
• Refer to INSTALLING RAIL OF CYLINDER BANK 1 .
• Refer to INSTALLING IGNITION COILS OF CYLINDER BANK 1 .
• Refer to INSTALLING CONTROL UNIT HOLDER FOR CYLINDERS 1 TO 4 .
• Refer to INSTALLING THE COVER PANEL OF THE MASTER DME CONTROL UNIT .
• Refer to INSTALLING THE COVER PANEL OF THE SLAVE DME CONTROL UNIT .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to CONNECTING BATTERY GROUND LEAD .
• Refer to EVACUATING AND CHARGING CONDITIONING .
• Refer to CHECKING ENGINE OIL LEVEL .