Removing the cylinder head

WARNING: Hot surfaces.
Risk of burning!

Perform all work only on components that have cooled down.

WARNING: Working on fuel system.
Risk of fire! Danger of explosion!

When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
No fire, sparks, open flames or smoking.

CAUTION: On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!

Wear suitable personal protective equipment.
Before performing any installation work, allow cooling system to cool down to less than 40°C.
Note warnings on cylinder head cover.

NOTE: RISK OF DAMAGE
Engine damage due to missing motor oil.
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train.

After replacing the cylinder head or the engine, do not start the engine without observing the repair notes.
It is imperative you observe the repair notes for cylinder head or engine replacement.
For additional information, see: REPAIR NOTES FOR CYLINDER HEAD OR ENGINE REPLACEMENT

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Preliminary work

Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to BRING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
Refer to REMOVE THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT
Refer to REMOVE THE COVER OF THE REAR RIGHT ENGINE COMPARTMENT .
Refer to REMOVE THE SEAL FOR THE HOOD REAR .
Refer to REMOVE LEFT AND RIGHT WIPER ARM .
Refer to REMOVE THE COWL COVER .
Refer to REMOVING TRAILING LINK AT SPRING BOLT .
Refer to REMOVING THE COWL UPPER PART IN THE CENTER .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING ACOUSTIC COVER AT REAR .
Refer to REMOVING THE SEALING FRAME ON LEFT AND RIGHT
Refer to REMOVING THE CENTER BULKHEAD LOWER PART .
Refer to REMOVE RESONATOR .
Refer to REMOVE CLEAN AIR PIPE .
Refer to REMOVE CHARGE AIR LINE .
Refer to REMOVING THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT .
Refer to REMOVING THE DME CONTROL UNIT .
Refer to REMOVE THE INTEGRATED POWER SUPPLY MODULE (PDM) .
Refer to REMOVE CONTROL UNIT BRACKET .
Refer to REMOVE THE CYLINDER HEAD COVER ACOUSTIC COVER .
Refer to REMOVING THE IGNITION COIL .
Refer to REMOVING ALL SPARK PLUGS .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
Refer to REMOVE THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
Refer to REMOVING THE RAIL WITH INJECTORS .
Refer to REMOVING FUEL DELIVERY LINE .
Refer to REMOVE HIGH PRESSURE PUMP .
Refer to REMOVING BOTH ACTUATORS .
Refer to REMOVING THE CYLINDER HEAD COVER .
Refer to REMOVE THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to IF INSTALLED: REMOVE THE TORSION STRUT ON THE RIGHT AND LEFT WHERE REQUIRED .
Refer to REMOVE COMPLETE EXHAUST SYSTEM .
Refer to REMOVE FRONT UNDERBODY PROTECTION AND/OR FRONT STIFFENING PLATE .
Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR AND THRUST FIELD RESPECTIVELY .
Refer to REMOVING THE STIFFENING PLATE .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to DRAIN THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to DRAIN THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
Refer to CONNECT THE COOLANT LINES FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to CONNECT THE COOLANT LINES FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to REMOVE CATALYTIC CONVERTER .
Refer to REMOVING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to REMOVE THE COOLANT RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to REMOVE THE COOLANT FEED LINE FOR THE EXHAUST GAS TURBOCHARGER .
Refer to REMOVE THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
Refer to REMOVE TANK VENT VALVE .
Refer to REMOVING THE INTAKE PLENUM .
Refer to BLOCKING ENGINE IN TDC FIRING POSITION .
Refer to REMOVING CHAIN TENSIONER .
Refer to REMOVE THE HEAT SHIELD AT THE CYLINDER HEAD
Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to REMOVE EXHAUST CAMSHAFT ADJUSTER .
Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to REMOVING INTAKE ADJUSTER .
Refer to REMOVE THE TEST GAUGES FOR SECURING THE CAMSHAFTS .

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: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

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 special tool 2 220 718 .

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Unlock plug connection (1) and disconnect.

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Loosen screw (1).
Release the oil feed line (2) on the exhaust turbocharger.

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Feed out the oil feed line (1) in the arrow direction on the exhaust turbocharger (2) and set aside.

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Loosen nut (1).
Feed out ground cable (2) and set it aside.

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Loosen screw (1).
Loosen screw (2).
Thread out holder (3) and set aside.

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Loosen screws (1).
Thread out holder (2) and set aside.

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Unlock plug connection (1) and disconnect.

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Unlock and loosen coolant line (1).
Unlock and disconnect the plug connection (2) on the knock sensor.
Unlock and disconnect the plug connection (3) on the coolant temperature sensor.

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Loosen screws (1).
Feed out the transmission wiring harness (2) on the wiring harness section (3) for the sensor system 1 and set aside.

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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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NOTE: The figure shows the rear of the engine.

Loosen screw (1).
Guide out and remove the cover (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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Insert and position the special tool 2 459 012 at the cylinder head.
Tighten the screws (1) of special tool 2 459 012 .

TIGHTENING TORQUES SPECIFICATION

Special tool to cylinder head
M8	Tightening torque	21.5 Nm

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Fasten the intake camshaft (2) with a standard open end wrench (1).
Loosen screw (3).
Feed out and remove the camshaft sensor wheel (4) on the guide pin (5).

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Release the cylinder head bolts in the sequence (5) to (1).

Fig 1: 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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Release the cylinder head bolts with the special tool 0 495 747 (11 8 580) in the sequence (10) to (1).

Fig 2: Cylinder Head Bolts 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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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 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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Hook the special tool 0 490 567 (11 0 020) on the special tool 2 220 718 .
Lift out the cylinder head (1) and the exhaust turbocharger with the help of a support person , with the special tool 2 220 718 and the special tool 0 490 567 (11 0 020) .
Ensure that the guide rails of the timing chain are not damaged.