Installing the cylinder head

• Check the fitting sleeves (1) for damage and a correct installation location, replace if necessary.

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  NOTE: TECHNICAL INFORMATION 
  Conduct the following operation with the assistance of a second person.
• Install the cylinder head (1) and the exhaust turbocharger with the workshop crane and the special tool 0 490 561 (11 0 000). 

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• Replace screws (1) to (10).

  Parts:  Screws

• Make sure that all threaded holes In the engine block are free of coolant, engine oil or other contaminations.
• Position the screws in the sequence (1) to (10).
  Fig 1: Cylinder Head Screws Tightening Sequence

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• Tighten cylinder head bolts using special tools 0 490 504 (00 9120)  and 0 495 747 (11 8 580)  in sequence (1) to (10).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Cylinder head to crankcase
  M11x1.5x188 11.9 Fit new cylinder head bolts.	1. Jointing torque	30 Nm
  	2. Angle of rotation	90°
  	3. Angle of rotation	180°
  M11x1.5x188 13.9 Fit new cylinder head bolts.	1. Jointing torque	30 Nm
  	2. Jointing torque	50 Nm
  	3. Angle of rotation	180°
  	4. Angle of rotation	180°

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• Install and tighten down screws (1).

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  TIGHTENING TORQUES SPECIFICATION
  
  

  Cylinder head bolt to timing case cover
  M8x40	Tightening torque	20 Nm

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• Secure the intake camshaft with an open-end spanner (1).
• Position the camshaft sensor wheel (3) and tighten the bolt (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Camshaft sensor wheel to intake camshaft
  M6	Tightening torque	10 Nm

• Use the tool as shown for the next operation to tighten the screw connections of the grounding cable and the acoustic cover.

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• Position acoustic cover and tighten with screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Acoustic cover, rear bottom on cylinder head
  M6x 16	Tightening torque	8 Nm

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• Lay wiring harness correctly and secure with the screw (3).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Cable clip on rear cylinder head/transmission
  M6x20	Tightening torque	8 Nm

• Position the grounding cable and tighten it with the bolt (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Grounding cable on cylinder head
  M6x 16	Tightening torque	8 Nm

• Clip in the cable (1) in the highlighted area on the acoustic cover (2).

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• Mount the slide rail (2).
• Tighten the screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Sliding rail to cylinder head
  M6x16	Tightening torque	8 Nm

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• Position the engine encapsulation (3) correctly.
• Connect connectors (1) and (2) lock.

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  NOTE: TECHNICAL INFORMATION 
  Make sure that the connections are locked correctly. The locks must engage audibly.
• Lock the coolant line (1) in place and plug onto the cylinder head.

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Follow-up Work 

• Refer to BLOCKING THE CAMSHAFTS
• Refer to INSTALLING THE INTAKE ADJUSTER .
• Refer to INSTALL VANOS CENTRAL VALVE OF THE INTAKE SIDE .
• Refer to INSTALL EXHAUST CAMSHAFT ADJUSTER .
• Refer to INSTALL VANOS CENTRAL VALVE OF THE EXHAUST SIDE .
• Refer to PRELOAD TIMING CHAIN .
• Refer to TIGHTENING THE VANOS CENTRAL VALVE .
• Refer to DISASSEMBLING ALL SPECIAL TOOLS
• Refer to CHECKING CAMSHAFT TIMING .
• Refer to INSTALLING THE THERMOSTAT ON THE TRANSMISSION OIL LINES .
• Refer to SECURING THE OIL SUMP ACOUSTIC COVER .
• Refer to INSTALLING CYLINDER HEAD COVER .
• Refer to INSTALLING BOTH ACTUATORS .
• Refer to PREPARE THE INJECTORS FOR INSTALLATION .
• Refer to INSTALLING THE RAIL
• Refer to PREPARE FOR THE INSTALLATION OF THE HIGH PRESSURE PUMP
• Refer to INSTALL HIGH PRESSURE PUMP .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
• Refer to INSTALLING ALL SPARK PLUGS .
• Refer to INSTALLING THE IGNITION COILS .
• Refer to INSTALLING THE INTAKE PLENUM .
• Refer to INSTALLING THE TANK VENT VALVE .
• Refer to INSTALLING THE DME CONTROL UNIT .
• Refer to INSTALL THE INTEGRATED POWER SUPPLY MODULE (PDM) .
• Refer to INSTALLING THE DME CONTROL UNIT .
• Refer to INSTALL THE COOLANT FEED LINE FOR THE EXHAUST TURBOCHARGER (COOLANT RETURN LINE REMOVED)
• Refer to ATTACH THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
• Refer to INSTALLING OIL FEED LINE FOR EXHAUST TURBOCHARGER (ENGINE ENCAPSULATION REMOVED)
• Refer to INSTALL THE COOLANT RETURN LINE FOR THE EXHAUST TURBOCHARGER (AUXILIARY COOLANT PUMP REMOVED)
• Refer to INSTALL FRONT ENGINE ENCAPSULATION .
• Refer to INSTALLING AUXILIARY COOLANT PUMP FOR THE EXHAUST TURBOCHARGER .
• Refer to INSTALL THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT .
• Refer to CONNECT THE COOLANT LINE OF HIGH-TEMPERATURE COOLANT CIRCUIT
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT
• Refer to INSTALL CATALYTIC CONVERTER .
• Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
• Refer to INSTALL THE REAR AXLE COVER .
• Refer to IF INSTALLED: INSTALL THE TORSION STRUT ON THE RIGHT AND ON THE LEFT AS NEEDED .
• Refer to INSTALL THE CONNECTING SUPPORTS ON THE TUNNEL
• Refer to INSTALLING THE MONITORING OXYGEN SENSOR .
• Refer to INSTALL FRONT OXYGEN SENSOR .
• Refer to INSTALLING THE HEAT SHIELD ON THE EXHAUST MANIFOLD .
• Refer to INSTALL THE CYLINDER HEAD COVER ACOUSTIC COVER
• Refer to INSTALL CHARGE AIR LINE
• Refer to INSTALLING CLEAN AIR PIPE .
• Refer to REMOVING INTAKE SILENCER HOUSING .
• Refer to REMOVE RESONATOR .
• Refer to INSTALLING CENTER BULKHEAD LOWER SECTION
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to FASTENING HIGH-VOLTAGE CABLES ON THE ELECTRICAL MACHINE ELECTRONICS .
• Refer to INSTALLING LEFT SEALING FRAME
• Refer to INSTALLING RIGHT SEALING FRAME
• Refer to INSTALLING THE CENTER BULKHEAD UPPER PART
• Refer to INSTALL TENSION STRUT ON SHOCK TOWER .
• Refer to INSTALLING COWL PANEL COVER .
• Refer to INSTALL LEFT AND RIGHT WIPER ARM .
• Refer to INSTALL THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to INSTALL THE SEAL FOR THE BONNET .
• Refer to TOPPING UP THE MOTOR OIL
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLER DEVICE
• Refer to FILL THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLER DEVICE
• Refer to CONNECT DIAGNOSIS SYSTEM; IF NECESSARY ENCODE AND PROGRAM I LEVEL .
• Refer to BLEEDING THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to BLEED THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to CHECKING/TOPPING UP OIL LEVEL IN AUTOMATIC TRANSMISSION .
• Refer to CHECK ENGINE OIL LEVEL .
• Refer to INSTALL ACOUSTIC COVER .
• Refer to INSTALLING THE REAR STIFFENING PLATE .
• Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT STIFFENING PLATE .
• Refer to INSTALL THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
• Refer to TAKE BONNET OUT OF THE SERVICE POSITION .