Installing Cylinder Head

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WARNING: Danger of objects or loads falling down

Risk of squashing or crushing
1. → Secure components to prevent them from falling down.

NOTIFICATION

Dirt and contamination

Risk of damage to units or components
1. → Protect components from dirt and contamination.
2. → Clean or replace dirty components.

Install cylinder head.
1. 1.1 Fit new cylinder-head gasket.
  Check installation position of cylinder-head gasket.
2. 1.2 Carefully place cylinder head in position.
  Check centering pins during positioning!
  
  The help of another person is required.
3. 1.3 Screw in new cylinder head screws -1 to 10- as far as they will go by hand using T10070 - Polydrive socket-wrench insert .
4. 1.4 Screw in new screws -Arrows- as far as they will go by hand.
5. 1.5 Tighten cylinder head screws in the sequence -1 to 10- using T10070 - Polydrive socket-wrench insert .
  > Initial - tightening 50 Nm (37 ftlb.)
  
  > Final tightening + 90°
  
  > Final tightening + 90°
6. 1.6 Tighten the screws -Arrows- .
  > Initial - tightening 4 Nm (3 ftlb.)
  
  > Final tightening +90°
Fig 1: Cylinder Head Screws Tightening Sequence
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Installing cylinder head
Install support for intake-air distributor -1- .

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Support for intake-air distributor
1. 2.1 Position support for intake-air distributor -1- .
2. 2.2 Screw on and tighten nut -2- .
  > Tightening - torque 20 Nm (15 ftlb.)
3. 2.3 Fit and tighten screw -3- .
  > Tightening - torque 10 Nm (7.5 ftlb.)
Connect and lock cable plug -2- .

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Hall sender, intake camshaft
Secure electric line for generator -1- .

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Electric line for generator
1. 4.1 Position electric line for generator -1- .
2. 4.2 Clip in clip -2- on holder -3- .

Clip cable plugs -1 to 4- into the holder and connect and lock them.

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Cable plug

1	Fuel injectors for direct fuel injection (DFI)
2	Valve for intake-air distributor flap
3	Knock sensor
4	Wiring harness for fuel pressure sensor, potentiometer for intake-air distributor flap, coolant temperature sensor, hall sender

Secure lines -1- .

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Lines on intake-air distributor
1. 6.1 Connect vacuum lines -5- .
2. 6.2 Route lines -1- and clip them into the clips -4- .
3. 6.3 Clip in clip -3- .
4. 6.4 Connect and lock plug-in coupling -2- .
Secure electric wire harness -1- .

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Electric wire harness
1. 7.1 Route electric wire harness -1- .
2. 7.2 Connect and lock cable plug -2- .
Connect and lock cable plug for fuel pressure sensor -1- .

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Electric plug connection for fuel pressure sensor (high-pressure sensor)
Secure electric wire harness for throttle housing -1- .

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Electric wire harness for throttle housing
1. 9.1 Route electric wire harness for throttle housing -1- .
2. 9.2 Clip in clips -3- .
3. 9.3 Connect and lock cable plug -2- .
Secure coolant line -1- .

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Line
1. 10.1 Position coolant line -1- .
2. 10.2 Fit and tighten screws -2 and 3- .
  > Tightening - torque 6 Nm (4.5 ftlb.)
Secure pressure hose -1- .

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Pressure hose
1. 11.1 Push on pressure hose -1- .
2. 11.2 Tighten screw-type hose clamp -2- .
  > Tightening - torque 5.5 Nm (4 ftlb.)
Connect and lock cable plug -2- .

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Temperature sensor
Secure coolant hose -1- .

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Coolant hose on cylinder head
1. 13.1 Connect coolant hose -1- .
2. 13.2 Position and secure spring band clamp -2- using VAS 6891 - spring band clamp pliers .