Installing the cylinder head

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.

Position the cylinder head (1) on the special tool 0 490 561 (11 0 000)and on the workshop crane.

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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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Guide in and install the cylinder head (1) carefully using the workshop crane and the special tool 0 490 561 (11 0 000) .
Replace the cylinder head bolts (1) to (10) .
Parts: Cylinder head bolts

Do not wash off the coating on the cylinder head bolts (1) to (10) .
Oil the contact surfaces of the screw heads of cylinder head bolts (1) to (10) lightly .
There must be no coolant, water or engine oil present in the threaded holes of the engine block.

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.

Fig 1: Cylinder Head Bolts Tightening Sequence

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Guide in and install the cylinder head bolts (1) to (10) .
Screw in the cylinder head bolts in the sequence (1) to (10) .
Tighten the cylinder head bolts with the special tools 0 490 504 (00 9 120) and 0 495 747 (11 8 580) in the sequence (1) to (10) .

TIGHTENING TORQUES SPECIFICATION

Cylinder head to crankcase
M11 Observe tightening sequence! Fit new cylinder head bolts.	1. Joining torque	30Nm
	2. Angle of rotation	90°
	3. Angle of rotation	180°

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	19Nm

Fig 2: Cylinder Head Bolts Tightening Sequence

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Insert and install the camshaft sensor wheel (3) .
Ensure that the camshaft sensor wheel (3) is correctly positioned on the guide pin (4) .
Affix the intake camshaft with an open-end wrench (1) .
Tighten down screw (2) .

TIGHTENING TORQUES SPECIFICATION

Camshaft sensor wheel to intake camshaft
M6x16	Tightening torque	8Nm

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Position the guide rail (2) .
Replace bearing journal (1) .
Parts: Bearing journal
Thread in the bearing journals (1) and install.
Make sure that the bearing journal (1) is correctly installed in the guide rail (2) .
Tighten the bearing pin (1) to the guide rail (2) .

TIGHTENING TORQUES SPECIFICATION

Bearing journal to cylinder head
M16x1.5 Replace bearing journal.		20Nm

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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	8Nm

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Insert and position the wiring harness section (2) for sensor system 1 .
Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATION

Wiring harness section for sensor system 1 to cylinder head
M6X16	Tightening torque	8Nm

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Feed in ground cable (4) and position.
Tighten down screw (3) .

TIGHTENING TORQUES SPECIFICATION

Ground cable to cylinder head
M6x12	Tightening torque	8Nm

Feed in and install coolant line (1) .

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Insert and install the holder (2) .
Make sure that the lock (1) engages audibly.

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Insert and install the holder (2) .
Tighten down screw (1) .

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Connect and lock the coolant line (1) to the cylinder head.
Make sure that the coolant line (1) engages audibly.
Connect connector (2) on the coolant temperature sensor and lock.
Ensure that the connector (2) audibly engages on the coolant temperature sensor.

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Feed in and install coolant line (2) .
Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATION

Coolant line to coolant pump/cylinder head
M6x20	Tightening torque	8Nm

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Loosen the screws (1) from the special tool 2 459 012 .
Guide the special tool 2 459 012 out and remove.

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Guide in and install the engine mount (1) in the arrow direction.

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Tighten down screw (1) .

TIGHTENING TORQUES SPECIFICATION

Right engine mount to side member
M12	Tightening torque	100Nm

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Tighten down screw (3) .

TIGHTENING TORQUES SPECIFICATION

Right engine mount to side member
M12	Tightening torque	100Nm

Insert and install the coolant line (2) .
Lock holder (1) .
Make sure the holder (1) engages audibly.

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Replace screws (1) .
Parts: Screws
Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATION

Right engine mount to cylinder head
M10 Replace screws.	Joining torque	40Nm
M10 Replace screws.	Angle of rotation	90°

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Replace the sealing ring (1) on the refrigerant line (2) .
Parts: Sealing ring
Insert and install the sealing ring (1) on the refrigerant line (2) .

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Insert and install the coolant line (4) .
Tighten down screw (3) .

TIGHTENING TORQUES SPECIFICATION

Connection point of intake pipe T1 to intake pipe T2
M6X27	Tightening torque	8Nm

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Lock holder (2) .
Make sure the holder (2) engages audibly.
Fasten the holder (1) on the coolant line (4) .
Disassemble the special tool 2 414 691 with the special tool 2 357 071 .

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Follow-up work

Refer to INSTALLING THE INTAKE ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE CAMSHAFT ADJUSTER .
Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to DISASSEMBLING ALL SPECIAL TOOLS .
Refer to INSTALLING CHAIN TENSIONER .
Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
Refer to PREPARING FOR THE INSTALLATION OF THE EXHAUST TURBOCHARGER .
Refer to INSTALLING EXHAUST TURBOCHARGER .
Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING CATALYTIC CONVERTER .
Refer to INSTALLING PROP SHAFT .
Refer to INSTALLING THE REAR HEAT SHIELD .
Refer to INSTALLING THE FRONT HEAT SHIELD .
Refer to INSTALLING EXHAUST SYSTEM .
Refer to INSTALLING THE CROSS-MEMBER ON THE REAR AXLE .
Refer to INSTALLING THE CONNECTING SUPPORT ON THE TUNNEL AT FRONT AND REAR .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to PREPARING FOR THE INSTALLATION OF THE HIGH PRESSURE PUMP .
Refer to INSTALLING HIGH PRESSURE PUMP .
Refer to INSTALLING BOTH ACTUATORS .
Refer to PREPARING THE INJECTORS FOR INSTALLATION .
Refer to INSTALLING INJECTORS .
Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
Refer to INSTALLING LAMBDA OXYGEN SENSOR .
Refer to INSTALLING ALL SPARK PLUGS .
Refer to INSTALLING THE IGNITION COILS .
Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE RAIL AND THE HIGH-PRESSURE PUMP .
Refer to INSTALLING CLEAN AIR PIPE .
Refer to INSTALLING THE SERVOMOTOR FOR THE ECCENTRIC SHAFT .
Refer to CONNECTING COOLANT LINE .
Refer to INSTALLING FAN COWL WITH ELECTRIC FAN .
Refer to INSTALLING CROSS CONNECTION .
Refer to INSTALLING INTAKE SILENCER HOUSING .
Refer to INSTALLING INTAKE PORT .
Refer to INSTALL ACOUSTIC COVER .
Refer to INSTALLING THE RIGHT STRUT BRACE .
Refer to INSTALLING THE REAR BULKHEAD .
Refer to INSTALLING THE UPPER BULKHEAD COVER PANEL .
Refer to INSTALLING THE STRUT BRACE .
Refer to INSTALLING REAR WINDSHIELD PANEL .
Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
Refer to INSTALLING FRONT WINDSHIELD PANEL COVER .
Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to INSTALLING THE FRONT RIGHT WHEEL ARCH COVER .
Refer to INSTALLING THE FRONT RIGHT WHEEL .
Refer to CHECKING ENGINE OIL LEVEL .
Refer to EVACUATE AND CHARGE CONDITIONING .
Refer to INSTALLING RIGHT HEADLIGHT .
Refer to ADJUSTING HEADLIGHTS .