Installing the cylinder head (engine removed)

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.
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 TORQUE SPECIFICATIONS

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 TORQUE SPECIFICATIONS

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 TORQUE SPECIFICATIONS

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 TORQUE SPECIFICATIONS

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 TORQUE SPECIFICATIONS

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 TORQUE SPECIFICATIONS

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 TORQUE SPECIFICATIONS

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 TORQUE SPECIFICATIONS

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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