Installing the cylinder head

Cylinder head screws

Fig 1: Cylinder Head Screws Tightening Sequence

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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 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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Insert, position and install the cylinder head (1) and exhaust turbocharger with the help of a support person, the workshop crane and special tool 0 490 567 (11 0 020) .
Ensure that the guide rails of the timing chain are not damaged.
Insert and install washer (2) .
Replace the 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 in the threaded holes of the crankcase.
Guide in and install 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.

Screw in the cylinder head bolts in the sequence (1) to (14) .
Tighten cylinder head bolts with special tool 0 495 747 (11 8 580) and 0 490 504 (00 9 120) in the order (1) to (14) .

Fig 2: Cylinder Head Bolts Tightening Sequence

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TIGHTENING TORQUES SPECIFICATION

Cylinder head to crankcase
M11X188 13.9 Observe tightening sequence! Fit new cylinder head bolts.	1. Joining torque	50 Nm
	2. Angle of rotation	180°
	3. Angle of rotation	180°

Replace cylinder head bolts (1) to (5) .
Parts: Cylinder head bolts
Make sure that there is no coolant, water or engine oil in the threaded holes of the timing case cover.
Screw in cylinder head bolts (1) to (5) .
Tighten the cylinder head bolts in the sequence (1) to (5) .

TIGHTENING TORQUES SPECIFICATION

Cylinder head bolt to timing case cover
M8x40 Replace screws.	Tightening torque	19 Nm

Fig 3: Cylinder Head Bolts Tightening Sequence

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Feed in and position camshaft sensor wheel (1) on the intake camshaft (2) .

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

TIGHTENING TORQUES SPECIFICATION

Camshaft sensor wheel to intake camshaft
M4 x35	Tightening torque	4.5 Nm

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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

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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Feed in and position holder (2) .
Tighten the screws (1) .

TIGHTENING TORQUES SPECIFICATION

Holder for the tank vent valve on crankcase
M6X16	tightening torque	8 Nm

Secure clamps (3) .
Connect and lock coolant line (1) .
Make sure that the coolant line (1) engages audibly.

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Connect connectors (1) and lock.
The connector (1) must engage audibly.

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Feed in and position holder (3) .
Tighten the screws (2) .

TIGHTENING TORQUES SPECIFICATION

Auxiliary coolant pump holder to cylinder head
M6	Tightening torque	8 Nm

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Tighten down screw (1) .

TIGHTENING TORQUES SPECIFICATION

Grounding cable on cylinder head
M6 x 16	Tightening torque	8 Nm

Connect connectors (1) and lock.
The connector (1) must engage audibly.

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Insert and install the holder (3) .
Guide in and install the pressure hose (2) for the differential pressure sensor.
Secure clamps (1) .

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Connect the plug connections (1) and lock.
The connectors (1) must engage audibly.
Secure the clamp (2) .

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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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Feed in and position holder (2) .
Tighten the screws (1) .

TIGHTENING TORQUES SPECIFICATION

Holder for the heat shield on crankcase
M6X16	tightening torque	8 Nm

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Follow-up work

Refer to INSTALLING THE OIL RETURN LINE IN THE CYLINDER HEAD .
Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
Refer to INSTALLING THE INTAKE ADJUSTER .
Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE 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 REMOVING ALL SPECIAL TOOLS .
Refer to INSTALLING CHAIN TENSIONER .
Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
Refer to INSTALLING THE INTAKE PLENUM .
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 COVER OF THE DME CONTROL UNIT .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to INSTALLING THE COOLANT RETURNING LINE BETWEEN THE EXHAUST TURBOCHARGER AND THE THERMOSTAT .
Refer to INSTALLING THE COOLANT FEED LINE PART 2 BETWEEN THE AUXILIARY COOLANT PUMP AND EXHAUST TURBOCHARGER .
Refer to INSTALLING THE OIL FEED LINE FOR CYLINDERS 1 TO 3 .
Refer to INSTALLING THE OIL FEED LINE FOR CYLINDERS 4 TO 6 .
Refer to INSTALLING THE OIL RETURN LINE FOR CYLINDERS 1 TO 3 .
Refer to INSTALLING THE OIL RETURN LINE FOR CYLINDERS 4 TO 6 .
Refer to FASTENING THE AUXILIARY COOLANT PUMP FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING BOTH ACTUATORS .
Refer to PREPARING THE INJECTORS FOR INSTALLATION .
Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 1 TO 3 .
Refer to INSTALLING THE HIGH PRESSURE PUMP FOR CYLINDERS 4 TO 6 .
Refer to INSTALLING THE HIGH PRESSURE PUMP OF CYLINDERS 1 TO 3 .
Refer to INSTALLING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL FOR CYLINDERS 4 TO 6 .
Refer to INSTALLING THE HIGH PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL FOR CYLINDERS 1 TO 3 .
Refer to INSTALLING FUEL DELIVERY LINE .
Refer to INSTALLING ALL SPARK PLUGS .
Refer to INSTALLING ALL IGNITION COILS .
Refer to INSTALLING CHARGE AIR PIPE CYLINDERS 4 TO 6 .
Refer to FASTENING THE CHARGE AIR CROSSING .
Refer to INSTALLING THE CONNECTING BRANCHES ON THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 1 TO 3 .
Refer to INSTALLING THE LEFT AIR DUCT .
Refer to INSTALLING FAN COWL .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING FRONT CROSS CONNECTION .
Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT .
Refer to INSTALLING THE TWO CATALYTIC CONVERTERS .
Refer to INSTALLING CENTER STIFFENING PLATE .
Refer to IF INSTALLED: INSTALLING THE RIGHT AND LEFT TORSION STRUTS .
Refer to INSTALLING TANK COVER ON LEFT AND RIGHT .
Refer to INSTALLING ALL OXYGEN SENSORS .
Refer to INSTALLING EXHAUST SYSTEM .
Refer to INSTALLING THE SECOND END PANEL UNDERNEATH .
Refer to INSTALLING THE COWL UPPER PART .
Refer to INSTALLING INTAKE FILTER HOUSING .
Refer to INSTALLING THE STRUT BRACE .
Refer to INSTALLING MOUNT OF HOOD SEAL ON THE LEFT AND RIGHT .
Refer to INSTALLING WINDSHIELD PANEL COVER .
Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
Refer to INSTALLING THE REAR HOOD SEAL .
Refer to INSTALLING THE FRONT SECTION OF THE FRONT WHEEL ARCH COVER ON THE LEFT AND RIGHT .
Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
Refer to INSTALLING THE FRONT LEFT AND RIGHT WHEELS .
Refer to PARTIALLY INSTALLING THE LEFT AND RIGHT FRONT WHEEL ARCH TRIM .
Refer to TOPPING UP THE MOTOR OIL .
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-SPECIFIC HIGH-VOLTAGE OR LOW-VOLTAGE VEHICLE ELECTRICAL SYSTEM .
Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to CHECKING ENGINE OIL LEVEL .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to TAKING HOOD OUT OF THE SERVICE POSITION .