Install the right valves

NOTE: RISK OF DAMAGE
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

Carefully slide the valve (1) in the cylinder head.
Check valves for tightness.

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Position the special tools 0 494 371 (11 9 006) , 0 494 372 (11 9 007) and 0 494 373 (11 9 008) on the cylinder head in the center in arrow direction.

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Shift the special tool 0 494 370 (11 9 005) in arrow direction via the edges of the special tool 0 494 371 (11 9 006) and lock it.
Turn the special tool 0 494 366 (11 9 001) with the cylinder head by 180°.

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NOTE:
RISK OF DAMAGE
Damage to the surface.
The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage.
- Do not use any metal-cutting tools.
Clean the contact surfaces (1).

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Fit special tool 0 490 746 (11 1 380) .
Replace the valve stem seal (1).
Parts: Valve stem seal
Oil and set the valve stem seal (1).

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Position the valve stem seals (2) on the valve (1).
Press the valve stem seal (2) by using the special tool 0 493 249 (11 6 380) downwards in arrow direction until it rests on the cylinder head.

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Install the valve spring (2) and the spring plate (1).

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Press down all valve springs with the special tool 0 496 143 (11 8 840) .

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Keep the valve spring pressed down with the special tool 0 496 143 (11 8 840) .
Position the valve shims (1) on the valve (2).
Carefully relieve the valve spring.
Turn special tool 0 494 362 (11 9 000) and the cylinder head by 180°.

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Unlock the special tool 0 494 370 (11 9 005) in arrow direction.
Remove the special tool 0 494 371 (11 9 006) .
Turn special tool 0 494 362 (11 9 000) and the cylinder head by 180°.

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Installing all hydraulic valve clearance compensating elements

NOTE: TECHNICAL INFORMATION
If the hydraulic valve clearance compensating elements are reused, they must be reinstalled at the same position.

Install all the hydraulic valve clearance compensating elements (1) in the direction of arrow.

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Install all roller cam followers

Observe the classification of roller cam followers.

The classification in digits from 1 to 5 has been printed on the roller cam follower.

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Classification	Idle speed
1	Repair case - slow engine speed when idling
2	Installed as standard/Initial installation
3	Installed as standard/Initial installation
4	Installed as standard/Initial installation
5	Repair case - high engine speed when idling

Install the roller cam follower (1) on the intake side.
Make sure that the roller cam follower (1) is correctly positioned on the hydraulic valve clearance compensating element (arrows) and the intake valves.

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Install the roller cam follower (1) on the exhaust side.
Make sure that the roller cam follower (1) is positioned correctly on the hydraulic valve clearance compensating elements (arrows) and the exhaust valves.

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Installing the intake camshaft for cylinders 1 through 6

Intake camshaft, right

Fig 1: Right Intake Camshaft Screws Tightening Sequence

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Check the plain rectangular compression ring (1) on the intake camshaft for damage and replace if necessary.
The snap-in lugs (arrows) of the plain rectangular compression ring must be locked in place.

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Make sure the roller cam follower (1) has been fitted correctly.
Coat all the bearing positions of the intake camshaft on the cylinder head with engine oil.

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Observe the camshaft identification.
All camshafts are identified and must never be mixed up.

E = intake side, 16 = cylinders 1 through 6

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Coat all bearing positions with motor oil.
Insert the intake camshaft without tension so that the identification is legible.
Observe the correct installation orientation of the roller cam follower (arrows).
The cams on cylinder 1 point upwards.

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Ensure that thrust bearing (1) of the intake camshaft is positioned correctly in the cylinder head.
The intake camshaft bearing cap of the thrust bearing (1) can only be mounted in one position.

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Position the lid (1) of the thrust bearing on the thrust bearing and hand-tighten the screws.
Position the high pressure pump bracket (2) and hand-tighten the screws.

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Coat all bearing positions with motor oil.
Observe the identification of the camshaft bearing caps.
All camshaft bearing cups are marked and must never be mixed up.

L = Cylinders 7 to 12, A = Exhaust side, 4 = Bearing position 4

R = Cylinders 1 to 6, E = Intake side

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Position all intake camshaft bearing caps (1) at their original installation location and hand-tighten the screws.

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Insert special tool 0 496 381 (11 9 893) .
Special tool 0 496 381 (11 9 893) must rest on the cylinder head without any gap after the exhaust camshaft is positioned.
If necessary, slightly rotate the intake camshaft.

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Tighten (apply) the bolts to the snug torque in the sequence (14) to (1) in increments of 180°.

TIGHTENING TORQUE SPECIFICATIONS

Camshaft bearing cap to cylinder head
M7x45	Joining torque	15 Nm
M7x45	Tightening torque	15 Nm

Fig 2: Right Intake Camshaft Bolts Tightening Sequence

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Ensure that all the intake camshaft bearing caps rest on the cylinder head without any gaps.

Tighten the screws in the sequence (14) to (1).

TIGHTENING TORQUE SPECIFICATIONS

Camshaft bearing cap to cylinder head
M7x45	Joining torque	15 Nm
M7x45	Tightening torque	15 Nm

Note the installation position (arrows) of the roller tappet during installation.
Installing roller tappet of high pressure pump.

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Installing the exhaust camshaft for cylinders 1 to 6

Exhaust camshaft, right

Fig 3: Right Exhaust Camshaft Screws Tightening Sequence

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Check plain rectangular compression rings (1) on the exhaust camshaft for damage and, if necessary, replace them.
The snap-in lugs (arrows) of the plain rectangular compression rings must be locked in place.

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Ensure that roller cam followers (1) fit correctly.
Coat all the bearing positions of the exhaust camshaft on the cylinder head with engine oil.

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Observe the camshaft identification.
All camshafts are identified and must never be mixed up.

(A) = Exhaust side, (16) = Cylinders 1 to 6

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Coat all bearing positions with motor oil.
Insert exhaust camshaft without tension so that the identification is legible.
Observe the correct installation orientation of the roller cam follower (arrows).
The cams on cylinder 1 point upwards.

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Ensure that thrust bearing (1) of the exhaust camshaft is positioned correctly in the cylinder head.
Ensure that the exhaust camshaft bearing cap of thrust bearing (1) can be mounted only in one position.

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Coat all bearing positions with motor oil.
Observe the identification of the camshaft bearing caps.
All camshaft bearing cups are marked and must never be mixed up.

(L) = Cylinders 7 to 12, (A) = Exhaust side, (4) = Bearing position 4

(R) = Cylinders 1 to 6, (E) = Intake side

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Position all exhaust camshaft bearing caps (2) at their original installation location and tighten (apply) the bolts until they are hand-tight.
Position the lid (1) of the thrust bearing on the thrust bearing and hand-tighten the screws.

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Insert special tool 0 496 381 (11 9 893) .
Special tool 0 496 381 (11 9 893) must rest on the cylinder head without any gap after the exhaust camshaft is positioned.
If necessary, twist exhaust camshaft somewhat.

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Tighten (apply) the bolts to the snug torque in the sequence (14) to (1) in increments of 180°.

TIGHTENING TORQUE SPECIFICATIONS

Camshaft bearing cap to cylinder head
M7x45	Joining torque	15 Nm
M7x45	Tightening torque	15 Nm

Fig 4: Right Exhaust Camshaft Bolts Tightening Sequence

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Ensure that all the exhaust camshaft bearing caps rest on the cylinder head without any gaps.
Tighten the screws in the sequence (14) to (1).

TIGHTENING TORQUE SPECIFICATIONS

Camshaft bearing cap to cylinder head
M7x45	Joining torque	15 Nm
M7x45	Tightening torque	15 Nm

Loosen screws (2) and (3).
CAUTION:
Heavy component.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
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Remove the cylinder head (1) from the special tool 0 494 362 (11 9 000) .
Clean the sealing surfaces on the cylinder head and exhaust manifold.
Replace the exhaust manifold seals (1).
Parts: Exhaust manifold seals
Position the exhaust manifold seals (1) with the bulge (arrows) to the outside.

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Position turbocharger.
Make sure that all retaining strips (1) are fitted again.

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Replace flange nuts.
Parts: Flange nuts

Tighten the 12-point collar nuts in the sequence (1) to (11).

TIGHTENING TORQUE SPECIFICATIONS

Exhaust manifold with turbocharger to cylinder head
M8 Flange nut Replace nuts.	tightening torque	15 Nm

Fig 5: Exhaust Manifold Collar Nuts Tightening Sequence

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NOTE: For a better overview the removed condition is shown here.

Release screws (1), (2) and (3).
Remove the special tool 2 451 701 from the exhaust manifold.

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Install spark plugs

NOTE: The description is provided only at one component. The procedure is the same for all other components.

NOTE: TECHNICAL INFORMATION
Do not drop spark plug into spark plug shaft! This can lead to a reduction of the electrode gap and can thus impair smooth running of the engine, especially in idle position.

Insert spark plug (1) into special tool 0 496 065 (12 1 230) .
Screw the spark plug (1) hand-tight into the engine using special tool 0 496 065 (12 1 230) .

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NOTE: TECHNICAL INFORMATION
Exclusively swiveling extensions may be used for the reversible ratchet. Rigid mounting tool and variable plug connections with rigid option may not be used; there is a risk that the insulator breaks.
Tighten the spark plugs with a torque wrench, the special tool 0 495 560 (12 1 220) and with an extension (1) with joint.

TIGHTENING TORQUE SPECIFICATIONS

Spark plugs
M12x1.25	tightening torque	23 Nm

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Follow-up work

Refer to INSTALLING THE CYLINDER HEAD .