Installing the cylinder head
CAUTION:
Heavy component.
Heavy components can lead to injury or damage.
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.
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.
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.
When replacing the cylinder head: The complete valve timing and the Valvetronic servomotor are already pre-assembled for new cylinder heads.
NOTE:
RISK OF DAMAGE
Damage to guide rails.
The application of great force can damage the guide rails of the timing chain.
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.
- With the help of a support person, the special tool 2 220 718 and the special tool 0 490 567 (11 0 020), feed in, position and install the cylinder head (1) and the exhaust turbocharger.
- Ensure that the guide rails of the timing chain are not damaged.
- Feed in and install all the washers (2).
- Replace all cylinder head bolts (1).
Parts: Cylinder head bolts
- Do not wash off the coating (1) of the cylinder head bolts.
- Lightly oil contact surfaces of cylinder head bolt screw heads.
There must be no coolant, water or engine oil present in the threaded holes of the engine block.
- Insert and install the cylinder head bolts (1).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. - Insert and install 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 0 495 747 (11 8 580) and 0 490 504 (00 9120) 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 30 Nm 2. Angle of rotation 90° 3. Angle of rotation 180° - Replace cylinder head bolts (1) to (5).
Parts: Cylinder head bolts
- Make sure that there is no coolant, water or engine oil in the threaded holes of the timing case cover.
- Screw in cylinder head bolts (1) to (5).
- 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 19 Nm - Replace bearing journal (1).
Parts: Bearing journal
- Feed in and install bearing journal (1) on the guide rail (2).
- Tighten the bearing journals (1).TIGHTENING TORQUES SPECIFICATION
Bearing journal to cylinder head Bearing journal
Replace the bearing journal!Tightening torque 22 Nm - Insert slide rail (2) and install.
- Tighten down screws (1).TIGHTENING TORQUES SPECIFICATION
Sliding rail to cylinder head M6x16 Tightening torque 8 Nm NOTE: RISK OF DAMAGE
Improper routing of cables and wiring harnesses.
Trapped, crushed or damaged cables may cause short circuits and malfunctions.- Route all cables without abrasions, do not trap and crush.
- Guide in and install the wiring harness section (2) for sensor system 1.
- Tighten down screw (1).TIGHTENING TORQUES SPECIFICATION
Cable bracket on rear cylinder head/transmission M6x20 Tightening torque 8 Nm NOTE: RISK OF DAMAGE
Improper routing of cables and wiring harnesses.
Trapped, crushed or damaged cables may cause short circuits and malfunctions.- Route all cables without abrasions, do not trap and crush.
- Guide in and install the transmission wiring harness (2) on the wiring harness section (3) for sensor system 1.
- Tighten down screws (1).TIGHTENING TORQUES SPECIFICATION
Cable bracket on rear cylinder head/transmission M6x20 Tightening torque 8 Nm - Guide in and install cover (2).
- Tighten down screw (1).TIGHTENING TORQUES SPECIFICATION
Cover to rear cylinder head M6 Tightening torque 8 Nm - Connect and lock connector (3) on the coolant temperature sensor.
- Ensure that the connector (3) audibly engages on the coolant temperature sensor.
- Connect and lock connector (2) on the knock sensor.
- Ensure that the connector (2) audibly engages on the knock sensor.
- Connect and lock coolant line (1).
- Make sure that the coolant line (1) engages audibly.
- Feed in the camshaft sensor wheel (4) on the guide pin (5) and position.
- Fasten the intake camshaft (2) with a standard open-end wrench (1).
- Tighten down screw (3).TIGHTENING TORQUES SPECIFICATION
Camshaft sensor wheel to intake camshaft M6x16
Replace screw.1. Tightening torque 5 Nm 2. Angle of rotation 90° - Connect connectors (1) and lock.
- Make sure the connector (1) engages audibly.
- Insert and install the holder (2).
- Tighten down screws (1).TIGHTENING TORQUES SPECIFICATION
Manifold bracket for intake air at cylinder head M6X16 Tightening torque 8 Nm - Insert and position the holders (3).
- Tighten down screws (1) and (2).TIGHTENING TORQUES SPECIFICATION
Holder for electrical auxiliary coolant pump to cylinder head M6 Tightening torque 7 Nm - Thread in ground cable (2) and install.
- Tighten nut (1).TIGHTENING TORQUES SPECIFICATION
Standard screw connection M6 M6 Tightening torque 8 Nm - Replace the sealing ring of the oil feed line (1) with the special tool 0 496 714 (00 9 030).
Parts: Sealing ring
- Feed in and install the oil feed line (1) in arrow direction on the exhaust turbocharger (2).
- Tighten the screw (1) on the oil feed line (2).TIGHTENING TORQUES SPECIFICATION
Oil feed line to exhaust turbocharger/crankcase M6x12 Tightening torque 8 Nm - Connect connectors (1) and lock.
- Make sure the connector (1) engages audibly.
- Unscrew the bolts (1) of the special tool 2 459 012.
- Feed out the special tool 2 459 012 at the cylinder head and remove.
Follow-up work
- Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
- Refer to INSTALLING THE INTAKE ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to INSTALL EXHAUST CAMSHAFT ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to DISASSEMBLING ALL SPECIAL TOOLS
- Refer to INSTALL CHAIN TENSIONER .
- Refer to CHECKING THE TIMINGS OF THE CAMSHAFT
- Refer to INSTALLING THE HOLDER FOR THE THERMOSTAT ON THE TRANSMISSION OIL LINES .
- Refer to INSTALLING THE THERMOSTAT ON THE TRANSMISSION OIL LINES .
- Refer to INSTALL COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
- Refer to INSTALLING THE HEAT SHIELD ON THE CYLINDER HEAD
- Refer to INSTALL INTAKE PLENUM .
- Refer to INSTALLING THE TANK VENT VALVE .
- Refer to INSTALL CONTROL UNIT BRACKET .
- Refer to INSTALL THE INTEGRATED POWER SUPPLY MODULE (PDM) .
- INSTALLING THE DME CONTROL UNIT
- Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to INSTALLING COOLANT FEED LINE FOR EXHAUST TURBOCHARGER .
- Refer to INSTALL THE COOLANT RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to INSTALL CATALYTIC CONVERTER .
- Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
- Refer to IF INSTALLED: INSTALL THE TORSION STRUT ON THE RIGHT, AND ON THE LEFT WHERE REQUIRED .
- Refer to INSTALL THE REAR AXLE COVER .
- Refer to INSTALL THE CONNECTING SUPPORTS ON THE TUNNEL .
- Refer to INSTALLING CYLINDER HEAD COVER .
- Refer to INSTALLING BOTH ACTUATORS .
- Refer to INSTALLING CENTER BULKHEAD LOWER PART
- Refer to INSTALLING LEFT SEALING FRAME .
- Refer to FASTENING HIGH-VOLTAGE CABLES ON THE ELECTRICAL MACHINE ELECTRONICS .
- Refer to INSTALLING ALL SPARK PLUGS .
- Refer to PREPARE THE INJECTORS FOR INSTALLATION .
- Refer to INSTALLING THE RAIL WITH INJECTORS .
- Refer to INSTALLING HIGH PRESSURE PUMP .
- Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
- Refer to INSTALLING FUEL DELIVERY LINE .
- Refer to INSTALL ALL IGNITION COILS .
- Refer to INSTALLING LAMBDA OXYGEN SENSOR .
- Refer to INSTALL THE CYLINDER HEAD COVER ACOUSTIC COVER .
- Refer to INSTALLING THE DRIVE BELT FOR THE COOLANT PUMP .
- Refer to INSTALL THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT .
- Refer to INSTALL CHARGE AIR LINE .
- Refer to INSTALL CLEAN AIR PIPE .
- Refer to INSTALL RESONATOR .
- Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
- Refer to FILL AND VENT THE HIGH-TEMPERATURE COOLANT CIRCUIT .
- Refer to FILL AND VENT THE LOW-TEMPERATURE COOLANT CIRCUIT .
- Refer to CHECKING/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION .
- Refer to CHECK ENGINE OIL LEVEL .
- Refer to INSTALLING ACOUSTIC COVER AT REAR
- Refer to INSTALLING THE CENTER COWL UPPER PART
- Refer to INSTALL TENSION STRUT ON SHOCK TOWER .
- Refer to INSTALLING WINDSHIELD PANEL COVER .
- Refer to INSTALL LEFT AND RIGHT WIPER ARM .
- Refer to INSTALL THE REAR RIGHT ENGINE COMPARTMENT COVER .
- Refer to INSTALL THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to INSTALL THE FRONT HOOD SEAL AT THE REAR .
- Refer to INSTALLING THE REAR THRUST FIELD .
- Refer to INSTALL FRONT UNDERBODY PROTECTION AND/OR FRONT STIFFENING PLATE .
- Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT THRUST FIELD .
- Refer to INSTALL REAR UNDERBODY PROTECTION .
- Refer to TAKE HOOD OUT OF THE SERVICE POSITION .