Removing the cylinder head

Preliminary work 

• Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVING SUSPENSION STRUT BRACE .
• Refer to REMOVING THE ACOUSTIC COVER .
• Refer to REMOVING THE FRONT-END STRUT .
• Refer to REMOVING THE SEALING 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 WINDSHIELD PANEL COVER .
• Refer to REMOVING TRAILING LINK AT SPRING BOLT .
• Refer to REMOVING THE CENTER COWL UPPER PART .
• Refer to REMOVING THE CENTER FIREWALL LOWER PART .
• Refer to REMOVING THE COVER FOR THE DME CONTROL UNIT .
• Refer to REMOVING THE DME CONTROL UNIT .
• Refer to REMOVING THE INTEGRATED SUPPLY MODULE (PDM) PARTIALLY .
• Refer to REMOVING THE CONTROL UNIT HOLDER .
• Refer to REMOVING THE CLEAN AIR PIPE FOR CYLINDERS 1 TO 3 .
• Refer to REMOVING THE LEFT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
• Refer to REMOVING THE RIGHT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
• Refer to REMOVING CLEAN AIR PIPE CYLINDERS 4-6 .
• Refer to PARTIALLY REMOVING THE COOLANT EXPANSION TANK OF THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to REMOVING THE HOLDER OF THE POSITIVE BATTERY CABLE .
• Refer to REMOVING LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 3 .
• Refer to REMOVING LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 4 TO 6 .
• Refer to REMOVING THE CONNECTING BRACKET FROM THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 4 TO 6 .
• Refer to REMOVING THE EXHAUST TURBOCHARGER HEAT SHIELD FOR CYLINDERS 1 TO 3 .
• Refer to REMOVING SEALING FOR FRONT HOOD .
• Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
• Refer to REMOVING UPPER CROSS CONNECTION .
• Refer to REMOVING THE REAR TOP CROSS CONNECTION .
• 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 FOR CYLINDERS 1 TO 6 .
• Refer to REMOVING BOTH HIGH PRESSURE PUMPS .
• 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 THE OIL FILLER CAP .
• Refer to REMOVING THE FRONT SPOILER .
• Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
• Refer to REMOVING THE LEFT AND RIGHT FRONT UNDERSHIELD .
• Refer to REMOVING THRUST FIELD .
• Refer to REMOVING THE FRONT BOTTOM SIDE COVER .
• Refer to REMOVING THE RIGHT HAND FRONT BOTTOM SIDE COVER .
• Refer to PARTIALLY RELEASING THE ENGINE OIL COOLER .
• Refer to DRAINING THE COOLANT FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• 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 CONNECTING THE COOLANT LINE TO THE RADIATOR .
• Refer to RELEASING THE OIL DRAIN PLUG .
• Refer to TIGHTENING THE OIL DRAIN PLUG .
• Refer to REMOVING EXHAUST SYSTEM .
• Refer to REMOVING INTERMEDIATE PIPE .
• Refer to REMOVING THE OXYGEN SENSOR MONITOR FOR THE CYLINDERS 1 TO 3 .
• Refer to REMOVING THE OXYGEN SENSOR MONITOR FOR THE CYLINDERS 4 TO 6 .
• Refer to REMOVING BOTH CATALYTIC CONVERTERS .
• Refer to LOOSENING THE ANTI-ROLL BAR LINK ON THE LEFT AND RIGHT FROM THE ANTI-ROLL BAR .
• Refer to REMOVING THE ANTI-ROLL BAR .
• Refer to REMOVING THE OIL RETURNING LINE FOR CYLINDERS 1 TO 3 .
• Refer to REMOVING THE OIL RETURNING LINE FOR THE CYLINDERS 4 TO 6 .
• Refer to REMOVING OIL FEED LINE FOR THE CYLINDERS 4 TO 6 .
• Refer to PARTIALLY RELEASING THE AUXILIARY COOLANT PUMP FOR THE EXHAUST TURBOCHARGER .
• Refer to REMOVING THE OIL FEED LINE FOR THE CYLINDERS 1 TO 3 .
• Refer to REMOVING THE COOLANT FEED LINE PART 2 BETWEEN THE AUXILIARY COOLANT PUMP AND EXHAUST TURBOCHARGER .
• Refer to REMOVING THE COOLANT RETURNING LINE BETWEEN THE EXHAUST TURBOCHARGER AND THERMOSTAT .
• Refer to REMOVING THE FAN COWL .
• Refer to REMOVING THE CHARGE AIR DUCT FOR CYLINDERS 1-3 .
• Refer to REMOVING THE CHARGE AIR DUCT FOR CYLINDERS 4-6 .
• Refer to REMOVING THE CHARGE AIR CROSSING .
• Refer to REMOVING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to REMOVING THE INTAKING PLENUM .
• Refer to REMOVING BOTH ACTUATORS .
• Refer to REMOVING THE CYLINDER HEAD COVER .
• Refer to BLOCKING THE ENGINE IN THE TDC FIRING POSITION .
• Refer to REMOVING CHAIN TENSIONER .
• Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKING ADJUSTER .
• Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
• Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKING ADJUSTER .
• Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
• Refer to REMOVING INTAKING ADJUSTER .
• Refer to REMOVING EXHAUST CAMSHAFT ADJUSTER .
• Refer to REMOVING THE TEST GAUGES FOR SECURING THE CAMSHAFTS .
• Refer to REMOVING THE OIL RETURNING LINE IN THE CYLINDER HEAD .

Cylinder head screws 

Fig 1: Cylinder Head Screws Loosening Sequence

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• 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 workshop crane 2 220 718 .

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• Unlock plug connection (1)  and disconnect.

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• Loosen screw (1)  .
• Loosen screws (2)  .
• Guide out and remove holder (3)  .

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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.

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• Loosen screws (1)  .
• Guide out holder (2)  and set it aside.
• Loosen clamp (3)  .

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• Loosen screws (1)  .
• Unlock transmission wiring harness (2)  on wiring harness section (3)  for sensor system 1 and set it to the side.

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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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• Loosen screws (1)  .
• Guide out and remove holder (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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• Shift 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 .

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• Release the cylinder head bolts in the sequence (5)  to (1)  .
  Fig 2: 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 3: 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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• Attach special tool 0 490 567 (11 0 020) to workshop crane.
• Lift out 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) .