Engine Installed

Remove both exhaust manifolds, refer to Exhaust System, Exhaust Manifolds, Service and Repair.

Note: After removing the exhaust manifolds, reinstall engine support arm with engine mounts and remove special tool 00 0 200.

Remove intake filter housing with air-mass flow sensor, refer to Powertrain Management.
Remove cylinder head cover, refer to Valve Cover, Service and Repair.
Remove all spark plugs, refer to Powertrain Management, Ignition System, Spark Plugs, Service and Repair.
Disconnect intake air manifold, refer to Intake Manifold, Service and Repair.

Open coolant drain plug on engine block. Drain and dispose of coolant.

Installation:
Tightening Torque, refer to Engine, Specifications, Mechanical.
Vent cooling system and check for leaks, refer to Cooling System, Service and Repair, Bleeding Cooling System and Checking For Water Leaks.

Remove coolant thermostat housing, refer to Cooling System, Thermostat, Engine Cooling, Service and Repair.





Remove coolant pipe.

Note:
If the coolant pipe cannot be fed out:
Release banjo bolt (1) and disconnect oil pressure line for VANOS adjustment unit.

Installation:
Replace O-ring on coolant pipe.
If necessary, replace sealing rings on banjo bolt (1).
Tightening Torque for banjo bolt (1), refer to Engine, Specifications, Mechanical.

Removal
Removal of cylinder head is described separately from installation.
Remove double VANOS adjustment unit, refer to Camshafts, Lifters and Pushrods, Camshaft, Engine, Service and Repair.
Remove camshafts with bearing strips, refer to Camshafts, Lifters and Pushrods, Camshaft, Engine, Service and Repair.





Release screw connection between timing case cover and cylinder head.





Release screws, remove chain guide.





Release cylinder head bolts from outside to inside in sequence 14 to 1.
Lift off cylinder head.

Installation
Installation of cylinder head is described separately from removal.
Clean sealing faces of cylinder head and engine block; if necessary, remove traces of sealing compound with hardwood spatula. Ensure that no gasket debris drops into the oil and coolant ducts.





Check that dowel sleeves are undamaged and correctly located.
Apply permanently elastic sealing compound Drei Bond 1209 (or equivalent) to joints to timing case cover.
Fit new cylinder head seal.





Note: A 0.3 mm thick cylinder head gasket is available for machined (milled) cylinder heads.

Caution:
Different cylinder head bolts:
M 10x95 for engines with cast iron engine block.
M10x110 for engines with aluminum engine block.
Cylinder head bolts always only be used once.
There must be no oil in the tapped holes of the engine block and the timing case cover.
Risk of cracking and distorted tightening values.





Put the cylinder head on.
Apply a light coat of oil to washer contact area and thread of new cylinder head bolts.
Tighten down cylinder head bolts in sequence 1 to 14.
Tightening Torque, refer to Engine Specifications.

Note: Use special tool 00 9 120 for torsion angle tightening.





Install chain guide.





Insert screws and tighten down screw connection between timing case cover and cylinder head.
Install camshafts.
Install double VANOS adjustment unit.
Assemble engine.