Disassembling and assembling cylinder head, right

Preliminary work 

• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
• Refer to REMOVING THE REAR DIFFUSER .
• Refer to IF INSTALLED: REMOVING THE TORSION STRUT ON THE RIGHT AND LEFT WHERE REQUIRED .
• Refer to REMOVING EXHAUST SYSTEM .
• Refer to REMOVING THE RETAINING BRIDGE .
• Refer to REMOVING THE RETAINING BRIDGE IN VEHICLES WITH A GASOLINE PARTICULATE FILTER .
• Refer to PARTIALLY REMOVING THE LEFT LAMBDA OXYGEN SENSOR .
• Refer to PARTIALLY REMOVING THE LAMBDA OXYGEN SENSOR .
• Refer to REMOVING THE LEFT OXYGEN SENSOR MONITOR .
• Refer to REMOVING THE RIGHT OXYGEN SENSOR MONITOR .
• Refer to REMOVING UPPER HEAT SHIELD .
• Refer to REMOVING THE LEFT HEAT SHIELD .
• Refer to REMOVING RIGHT HEAT SHIELD .
• Refer to REMOVING THE COVER OF THE REAR RIGHT ENGINE COMPARTMENT .
• Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT .
• Refer to REMOVING LEFT AND RIGHT WIPER ARM .
• Refer to REMOVING THE COWL COVER .
• Refer to REMOVING TRAILING LINK AT SPRING BOLT .
• Refer to REMOVING THE COWL UPPER PART IN THE CENTER .
• Refer to LIFTING THE HEAT SHIELD .
• Refer to REMOVING THE CATALYTIC CONVERTER FOR CYLINDERS 1 TO 4 .
• Refer to REMOVING THE CATALYTIC CONVERTER FOR CYLINDERS 5 TO 8 .
• Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
• Refer to REMOVING BOTH FRONT-END STRUTS .
• Refer to REMOVING FRONT CROSS CONNECTION (FRONT-END STRUT REMOVED) .
• Refer to REMOVING THE REAR TOP CROSS CONNECTION .
• Refer to REMOVING FAN COWL .
• Refer to REMOVING DRIVE BELT .
• Refer to RELEASING LEFT CHARGE AIR LINE PARTIALLY .
• Refer to PARTIALLY RELEASING THE RIGHT CHARGE AIR LINE .
• Refer to REMOVING THE FRONT RIGHT LOWER WHEEL ARCH COVER .
• Refer to REMOVING THE LEFT FRONT BOTTOM WHEEL ARCH COVER .
• Refer to REMOVING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
• Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR AND THRUST FIELD RESPECTIVELY .
• Refer to DRAINING COOLANT .
• Refer to DRAINING THE COOLANT FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to REMOVING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT (CHARGE AIR COOLER) .
• Refer to REMOVING BOTH CHARGE AIR COOLERS .
• Refer to REMOVING THE CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to REMOVING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to REMOVING THE IGNITION COILS OF CYLINDERS 1 AND 5 .
• Refer to REMOVING IGNITION COIL OF CYLINDER BANK 1 .
• Refer to REMOVING FUEL DELIVERY LINE .
• Refer to REMOVING RIGHT HIGH-PRESSURE PUMP .
• Refer to REMOVING RIGHT RAIL .
• Refer to REMOVING THE INJECTORS FOR CYLINDERS 1 TO 4 .
• Refer to REMOVING THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 1 TO 4 .
• Refer to REMOVING THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 5 TO 8 .
• Refer to REMOVING FRONT HEAT SHIELD .
• Refer to PARTIALLY RELEASING THE GUIDE TUBE FOR THE OIL DIPSTICK .
• Refer to REMOVING VANOS SOLENOID ACTUATOR, EXHAUST OF CYLINDER BANK 1 .
• Refer to REMOVING THE VANOS SOLENOID ACTUATOR INTAKE OF CYLINDER BANK 1 .
• Refer to REMOVING RIGHT CYLINDER HEAD COVER .
• Refer to REMOVING THE SEALING CAP ON THE CYLINDER HEAD OF THE CYLINDER BANK 1 .
• Refer to MOVING THE CRANKSHAFT TO THE INSTALLATION POSITION TO ADJUST THE TIMINGS .
• Refer to CHECKING THE VANOS ADJUSTER OF CYLINDER BANK 1 .
• Refer to RELIEVING THE CHAIN TENSIONER AT CYLINDER BANK 1 FOR CHECKING OR SETTING THE VALVE TIMINGS .
• Refer to REMOVING HYDRAULIC CHAIN TENSIONER OF CYLINDER BANK 1 .
• Refer to PRELOADING THE TIMING CHAIN OF CYLINDER BANK 1 .
• Refer to FIXING THE ENGINE IN THE INSTALLATION POSITION ON CYLINDER 1 (SET VALVE TIMINGS) .
• Refer to REMOVING BOTH RIGHT VANOS ADJUSTERS .
• Refer to REMOVING SPECIAL TOOL FOR FIXING CAMSHAFTS ON BANK 1 .
• Refer to REMOVING THE SPECIAL TOOL TO PRETENSION THE TIMING CHAIN AT CYLINDER BANK 1 .
• Refer to REMOVING RIGHT CYLINDER HEAD .

Removing the stud bolts on the right cylinder head (cylinder head removed) 

• Loosen nuts (1)  .
• Guide out and remove the sliding frame (2)  .
• Guide out and remove the right exhaust manifold (3)  .

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• Remove the (1)  exhaust manifold seal.

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• Remove the (1)  stud bolts.

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Removing the engine venting connector of cylinder bank 1 

• Release venting connector (1)  .

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Removing the spark plugs of cylinder bank 1 (cylinder head removed) 

• Unscrew the spark plugs with the special tool 0 495 560 (12 1 220) and an extension with joint.

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• Unscrew spark plugs (1) with special tool 0 495 560 (12 1 220) and extension with joint.

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Removing the engine mounting bracket of cylinder bank 1 

• Loosen screws (2)  .
• Remove the engine mounting bracket (1)  .

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Attaching cylinder head of bank 1 to assembly jig, and removing and installing valves 

Removing the right intake plenum (cylinder head removed) 

• Loosen screws (1)  .
• Loosen screws (2)  .
• Guide out right intake plenum.

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Removing right Valvetronic servomotor (cylinder head removed) 

• Loosen screws (3)  .
• Turn Valvetronic servomotor eccentric shaft (2)  counterclockwise to loosen and remove the Valvetronic servomotor (1)  .

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Installing the cylinder head of cylinder bank 1 on the assembly jig 

• Get the set of special tools 0 495 187 (00 2 300) ready.

Number	Description
1	Assembly jig
2	Flange
3	Crank
4	cover panel
5	shelf
6	Rear shaped part
7	Collecting vessel
8	Front shaped part
9	Front wheel
10	Rear wheel with stop
11	Rubber mat

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• Get the set of special tools 0 494 362 (11 9 000) ready.

Number	Description
1	Device
2	Rod
3	Adapter
4	Lug
5	Quick tensioning device
6	Aluminum frame insert
7	Shaped part
8	Plastic shaped part
9	lever
10	hook
11	Valve spring cage
12	Valve spring cage
13	Valve spring cage
14	Valve spring cage
15	Valve spring cage
16	Valve spring cage
17	Valve spring cage

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• Position flange (1)  on the assembly jig (2)  .
• Tighten screws (arrows).

Flange to assembly jig
M14X30	Tightening torque	135 Nm

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• Slide the device (1)  in arrow direction onto the flange (2)  and install.
• Make sure that the lock (3)  engages audibly.

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• Loosen screw (1)  .
• Feed out rod (2)  in arrow direction and set aside.

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• Keep the screws from the set of special tools 0 496 408 (11 8 080) ready. 
• The washer of the cylinder head bolt (1)  must be used.

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• Apply the cylinder head (1)  hand-tight on the special tool 0 494 362 (11 9 000) in the attachment point area using the screws from the set of special tools 0 496 408 (11 8 080)  .

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  Removing the exhaust camshaft of cylinder bank 1 

• Remove the roller tappet (1)  from high pressure pump bracket (2)  .

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• Mark the guide bearing shells of the exhaust camshaft from (A1)  to (A4)  as shown in the graphic.

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• Release the screws of the guide bearing in the order (1)  to (10)  by half a rotation at a time.
• Remove the guide bearing shells of the exhaust camshaft.
• Remove the exhaust camshaft.

Remove the roller cam follower of the exhaust side of cylinder bank 1 

• Detach and remove the roller cam followers (1)  on the exhaust side from hydraulic valve clearance compensating elements (arrows).
• Place all roller cam followers in order in special tool 0 495 105 (11 4 480) .

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Removing hydraulic valve clearance compensating elements on exhaust side of bank 1 

• Pull all exhaust hydraulic valve clearance compensating elements of the exhaust side (1)  up and off.
• Place all hydraulic valve clearance compensating elements in proper order on the special tool 0 495 105 (11 4 480) .

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Remove torsion springs 

Precondition 

If the Valvetronic servomotor is installed, the eccentric shaft must be released via the Valvetronic servomotor. 

• The modified locking rods 2 411 031  must be installed on the special tool 2 249 160  .

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• Position special tool 2 249 160  at a downward angle on the torsion spring panel (2)  .

  The lug (1)  should be positively locked with the torsion spring panel (2)  .

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• The guide pins (2)  in the special tool 2 249 160  should be positively locked with the recesses in the torsion spring panel (1)  .

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• Press lever (1)  on the special tool 2 249 160  in the direction of arrow until the latch mechanisms (2)  lock.

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• Release bolt on the plate of the torsion spring in the area (1)  .
• Guide out special tool 2 249 160 (2)  with the torsion spring and the panel of the torsion spring.

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• Connect separate components of the special tool 2 249 160 (3)  to (2)  and secure with the locking pin (1)  .

  The locking pin (1)  should audibly engage.

• Clamp special tool 2 249 160  in a standard vice at area (2)  .

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• Use the lever (1)  to push special tool 2 249 160  forward to pretension the torsion springs (3)  .
• Pull lever (2)  down to release the retaining pins (5)  from the anti-twist locks (4)  .
• Carefully release tension on the lever (1)  on the special tool 2 249 160  .
• Remove the torsion spring with the lock plate (3) and place it in the special tool 0 495 105 (11 4 480) in an ordered position.
• Repeat steps for all torsion springs.

Twist camshaft if necessary.

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Removing the sliding block of cylinder bank 1 

• Position the special tool 2 249 166  on the intake camshaft (1)  in the area of the sliding block (2)  to be disassembled.

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• Preload the sliding block (3)  with the special tool 2 249 166 (2)  in direction of arrow.
• Loosen screw (1)  .
• Remove the gate (3)  and place it arranged in order into 0 495 105 (11 4 480) .
• Repeat the step for all the gates.

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Removing the intake camshaft of cylinder bank 1 

• Mark guide bearing shells of the intake camshaft as shown in the graphic from (E1)  to (E5)  .
• Slacken the screws of the guide bearings with position numbers (1)  and (4)  in multiple steps by one half turn at a time.
• Remove guide bearing shells.
• Remove intake camshaft.

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Remove the intermediate lever of the intake side 

• Feed out the intermediate lever (1)  upward from the roller cam follower (2)  and the cam (3)  of the eccentric shaft.
• Repeat the step for all intermediate levers (1)  .

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Removing the roller cam follower of the intake camshaft 

• Release and remove the roller cam follower (2)  on the intake side from the hydraulic valve clearance compensating element.
• Place all roller cam followers in order in special tool 0 495 105 (11 4 480) .
• Remove all hydraulic valve clearance compensating elements (1)  to the top.
• Place all hydraulic valve clearance compensating elements into the special tool 0 495 105 (11 4 480) along with the roller cam followers in order.

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Removing the eccentric shaft of cylinder bank 1 

• Release all the screws in the marked areas (1)  .

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• Twist the eccentric shaft (2)  counterclockwise.
• Label the bearing brackets as shown in the graphic.
• Orderly set down bearing brackets (E1)  to (E5)  in the special tool 0 495 105 (11 4 480) .
• Guide out the eccentric shaft (2)  toward the top and remove it.

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Setting up cylinder head of bank 1 on special tool 119000 

• Prepare plastic shaped parts (1)  with the shaped parts (2)  and aluminum frame insert (3)  .

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• Quick clamping devices (1) on special tool 0 494 362 (11 9 000) (2) must be unlocked.
• Insert aluminum frame insert (2)  .

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• Position cylinder head on special tool 0 494 362 (11 9 000) .
• The valves in area (2)  must be aligned with the plastic elements (1)  .

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• Cylinder head (1) on special tool 0 494 362 (11 9 000) must be hand-tightened in the area of the attachment points with screws from the set of special tools 0 496 408 (11 8 080)  .

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• Lock quick clamping device (1) on special tool 0 494 362 (11 9 000) (2) in arrow direction.

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• Select the correct valve spring cage from the set of special tools 0 494 362 (11 9 000) .

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• Complete special tool 0 494 362 (11 9 000) .
• Select suitable position on the lever of the valve spring cage (1)  and secure hand-tight with the screws.
• Hook with damper (2)  can be fixed on special tool 0 494 362 (11 9 000) for easier disassembly of the valve shims.

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Remove valves 

• Position valve spring cage (1)  on the valve head.
• Push special tool 0 494 362 (11 9 000) down on the lever (3)  and attach on the hook (4)  .
• Remove valve shims (2)  with magnet.
• Detach hook (4)  .
• Relieve lever (3)  .

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• Remove valve spring cup (1)  .
• Remove valve spring (3)  and place it arranged in order in the special tool 0 495 105 (11 4 480) .

  Observe color coding and direction of installation and mark and identify where required.

• hen replacing the valves, the cylinder head must be detached from the cylinder head 0 494 362 (11 9 000)  .
• Repeat step for all valves.

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  Replacing the valve stem seals 

  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.
  NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
• Disassemble the valve stem seal (1)  in arrow direction with the special tool 0 490 796 (11 1 480) .

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• Remove oil and dirt from the contact surface (1)  .

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• During installation of the valve stem seal, use the special tool 0 490 797 (11 1 960) .

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• Insert and install special tool 0 490 797 (11 1 960) on the valve (1).

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• Insert and install valve stem seal (1)  on the special tool 0 490 797 (11 1 960) .

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• Guide the special tool 0 490 797 (11 1 960) out and remove.

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• Press the valve stem seal (1)  with the special tool 0 493 249 (11 6 380) onto the cylinder head until the stop.

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• Make sure the valve stem seal (1)  is properly positioned on the cylinder head (2)  .

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  Installing valves 

• When replacing the valves, the cylinder head must be fastened on the special tool 0 494 362 (11 9 000) .
• Observe the color coding and direction of installation. 

  Position the valve spring (3)  .

• Position the valve spring cup (1)  .

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• Position valve spring cage (1)  on the valve head.
• Push special tool 0 494 362 (11 9 000) down on the lever (3)  and attach on the hook (4)  .
• Insert the valve shims (2)  with a magnet or screwdriver.
• Detach hook (4)  .
• Relieve lever (3)  .
• Repeat step for all valves.

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  Checking the valves for tightness 

  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.
  WARNING: Contact with hazardous fluids. 
  Hazardous to health! 

  • Note and follow safety instructions on containers.
  • Conduct all work in appropriate personal protective equipment only.
• Coat all intake valves with fuel in area (1)  on the cylinder head.

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• Coat all exhaust valves with fuel in area (1)  on the cylinder head.

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  Check 

• Does fuel escape from valves (1)  and (2)  on the cylinder head?

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  Result 

  » No fuel escapes from the valves or valve seats.

  Measure

  • Continue the repair with the next step.

  Result 

  » Fuel escapes from the valves or valve seats.

  Measure 

  • Clean valves, countersink and replace if necessary.

  Installing the eccentric shaft of cylinder bank 1 

• Coat the bearing positions of the eccentric shaft with motor oil.
• Insert the eccentric shaft (2)  from below and install.
• Pay attention to the installation locations of the guide bearing shells (E1)  to (E5)  .
• Position bearing brackets as shown in the illustration.

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  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.

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• Tighten all screws in the marked areas (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Eccentric shaft bearing brackets
  Screw M6	Tightening torque	10 Nm

  Releasing tension on special tool 119000 

  CAUTION: Heavy component. 
  Heavy components can lead to injury or damage. 

  • Remove and install heavy components with the aid of another person/other persons.
• Release quick clamp device (1)  from the special tool 0 494 362 (11 9 000) (2)  in the direction of the arrow.
• Remove aluminum frame insert (2)  .

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  Installing the roller cam follower of the intake camshaft 

  NOTE: The description is provided only at one component. The procedure is the same for all other components.
• If a new hydraulic valve clearance compensating element has not been installed, install in the same position. 
• Install all hydraulic valve clearance compensating elements (1)  downward.
• If the roller cam followers are not being replaced, install the roller cam followers in the same position. 
• Install the roller cam follower (2)  .

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  Checking the intermediate lever classification 

  NOTE: TECHNICAL INFORMATION 
  All intermediate levers are classified. Only one classification may be used per engine.
  All intermediate levers must be reinstalled in the same positions in an engine which has already been in use.
• Checking the intermediate lever classification (arrows).

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  Installing intermediate lever on intake side 

• Position intermediate lever (1)  so that it contacts roller cam follower (2)  and cam of eccentric shaft (3)  .
• Repeat the step for all intermediate levers (1)  .

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  Install intake camshaft of bank 1 

• Plastic rings (1)  are maintenance free and do not need to be replaced.
• Check plastic rings for damage, replace if necessary.

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  NOTE: TECHNICAL INFORMATION 
  The rocker arms may slip slightly when the camshaft is positioned. Make sure rocker arms are correctly positioned on the hydraulic valve clearance compensating elements and on valves.

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• Position intake camshaft.
• When screwing the camshafts, make sure the valves have free movement. 
• Position guide bearing shells according to marks (E1)  to (E5)  .
• Join the screws of the guide bearings with position numbers (1)  and (4)  in multiple steps by one half turn at a time until flush.
• Tighten the screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake/exhaust camshaft
  M6	Tightening torque	10 Nm

• Tighten down screws (4)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake/exhaust camshaft
  M6	Tightening torque	10 Nm

• All intermediate levers (3)  must rest correctly on the idler pulley (1)  and on the camshaft (4)  .
• All intermediate levers (3)  must rest correctly on the idler pulley (2)  and on the eccentric shaft (5)  .

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  Install sliding blocks of bank 1 

• Position the special tool 2 249 166  on the intake camshaft (1)  in the sliding block (2)  area.
• Remove the oil and dirt from the sliding block (3)  .
• Position the sliding block (3)  and abut with the screw (1)  .
• Preload the sliding block (3)  with the special tool 2 249 166 (2)  in direction of arrow.
• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Sliding block on cylinder head
  Screw M7x35 10.9	Tightening torque	20.5 Nm

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• Relieve the special tool 2 249 166 (1)  and feed it out of the camshaft (2)  and place aside.
• Repeat the step for all the gates.

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  Installing torsion springs 

  CAUTION: Spring preload. 
  Injury hazard! 

  • The use of the specified special tool (tool) is mandatory.
  • Carry out the described steps properly.
  NOTE: The description is provided only at one component. The procedure is the same for all other components.
• Position the torsion springs (3)  on the special tool 2 249 160  .

  The lug in area (1) must be positively locked with the torsion spring panel (3). 

  The guide pins (2) in the special tool 2 249 160 must be positively locked with the recesses in the torsion spring panel (3). 

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• Connect individual parts of the special tool 2 249 160 (3) to (2) and secure with the locking pin (1). 

  The locking pin (1)  should audibly engage.

• Clamp special tool 2 249 160  in a standard vice at area (2)  .

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• Use the lever (1)  to push special tool 2 249 160  forward to pretension the torsion springs (3)  .
• The retaining pins (5)  should be secured to the detent (4)  on both sides.
• Do not operate the release lever (2). 

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• Feed in the special tool 2 249 160  with the torsion spring.
• Position torsion springs in the intermediate levers on the cylinder head.

  The ends of the torsion springs (1) must be located in the recesses of the intermediate lever (2)  .

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• Tighten screw at area (1)  on the torsion spring panel.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Torsion spring on cylinder head
  M6x20 screw	tightening torque	8.8 Nm

• The special tool 2 249 160 (2)  must be pretensioned.

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• Press lever (1)  on the special tool 2 249 160  in the direction of the arrow until the detents (2)  release.

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• Press the lever (1)  on the special tool 2 249 160  forward to keep the torsion springs (3)  tensioned.
• Pull lever (2)  down to release the retaining pins (5)  from the anti-twist locks (4)  .
• Carefully release tension on the lever (1)  on the special tool 2 249 160  .
• Remove the special tool 0 495 105 (11 4 480) .
• Repeat steps for all torsion springs.

  Twist camshaft if necessary.

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  Installing hydraulic valve clearance compensating elements on exhaust side of cylinder bank 1 

• Install all exhaust hydraulic valve clearance compensating elements of the exhaust side (1)  downward.

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  Installing roller cam follower of the exhaust side of bank 1 

• Position roller cam followers (1)  on exhaust side on the hydraulic valve clearance compensating elements.

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  Install exhaust camshaft of the bank 1 

• Plastic rings (1)  are maintenance free and do not need to be replaced.
• Check plastic rings for damage, replace if necessary.

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• Position exhaust camshaft.
• Position exhaust camshaft guide bearing shell.
• Screw in guide bearing screws in the order (1)  to (10)  by a half turn at a time until they can no longer be tightened.
• Tighten screws in the order (1)  to (10)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake/exhaust camshaft
  M6	Tightening torque	10 Nm

  Fig 2: Exhaust Camshaft Guide Bearing Shells Screws Tightening Sequence

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• Install roller tappet (1)  into the high pressure pump bracket (2)  .

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  Remove the cylinder head of cylinder bank 1 from the assembly jig 

  CAUTION: Heavy component. 
  Heavy components can lead to injury or damage. 

  • Remove and install heavy components with the aid of another person/other persons.
• Release the screws 0 496 408 (11 8 080)  at the special tool 0 494 362 (11 9 000) in the area of the attachment points.
• Remove the cylinder head (1)  .

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  Install Valvetronic servomotor, right (cylinder head removed) 

  NOTE: TECHNICAL INFORMATION 
  The work must be performed with vehicle care to prevent component damage.
• If necessary, lever the radial shaft seal (1)  out of the cylinder head using a standard tool.

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• Replace radial shaft seal (1)  at front.

  Parts:  Radial shaft seal

• Grease the gearing on the worm drive in area (2)  using lubricating grease.

  Parts:  lubric. grease

  CONSUMABLE DESCRIPTION
  
  

  Lubricating grease  Longtime PD-1

  400 g, Cartridge

  83192160340

• Screw in the Valvetronic servomotor (1)  evenly with the shaft (2)  over the gearing of worm drive up to the stop.
• Secure screws (3)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Valvetronic servomotor on cylinder head
  M6x16-8.8	Tightening torque	9.6 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing right intake plenum (cylinder head removed) 

• Replace the seal (4)  .

  Parts:  Seal

• Only during replacement of the intake plenum: 

  Loosen screws (1)  .

  Unlock pressure sensor (2)  on the retaining tab (3)  .

  Remove pressure sensor (2)  .

  Position pressure sensor (2)  .

  Retaining tab (3)  must audibly lock in.

  Tighten down screws (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Pressure sensor
  screw	Tightening torque	3 Nm

• Position the left intake plenum.
• Tighten down screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake plenum
  M6 screw	Tightening torque	10 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Tighten down screws (2)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake plenum
  M8 screw	Tightening torque	21.4 Nm

  Install engine mounting bracket of bank 1 

• Position engine mounting bracket (1)  .
• Tighten screws (2)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Engine suspension element
  M8x22 screw	Tightening torque	20 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing the spark plugs of bank 1 (cylinder head removed) 

  NOTE: The description is provided only at one component. The procedure is the same for all other components.
• Insert spark plug (1) into special tool 0 496 065 (12 1 230) .
  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.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Make sure the spark plug does not fall into the spark plug shaft.
• First screw spark plugs into the engine using special tool 0 496 065 (12 1 230) and tighten manually.
  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 spark plugs (1)  with a torque wrench, special tool 0 496 065 (12 1 230) and extension with joint.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Spark plugs
  M12x1.25	Tightening torque	23 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing venting connector of bank 1 

• Replace the venting connector (1)  .

  Parts:  Venting connector

• Tighten the venting connector (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Venting connector/special tool to cylinder head
  M8x1 Replace the venting connector.	Tightening torque	15 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing stud bolts on the right cylinder head 

  Precondition 

  Cylinder head is removed.

• Clean sealing surfaces (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Replace the stud bolt (1)  .

  Parts:  Stud bolts

• Tighten the stud bolts (1)  and check for correct fit.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Stud bolt on cylinder head
  M8x50	Replace the stud bolt. tightening torque	20 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Replace the exhaust manifold seal (1)  .

  Parts:  Exhaust manifold seal

• Position the exhaust manifold seal (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• The installation position of the seal (1) must be adhered to. 

  The seal (1)  must be installed with the side of the bead (2)  (seal depth) towards the exhaust manifold (3)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Insert and position the exhaust manifold (3)  at left.
• Position the sliding rail (2)  .
• Tighten nuts (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Exhaust manifold to cylinder head
  M8 Replace nuts.	tightening torque	15 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

Follow-up work 

• Refer to INSTALLING THE RIGHT CYLINDER HEAD .
• Refer to INSTALLING BOTH RIGHT VANOS ADJUSTERS .
• Refer to REMOVING THE SPECIAL TOOL TO PRETENSION THE TIMING CHAIN AT CYLINDER BANK 1 .
• Refer to INSTALLING THE HYDRAULIC CHAIN TENSIONER OF CYLINDER BANK 1 .
• Refer to INSTALLING THE SEALING CAP ON THE CYLINDER HEAD OF CYLINDER BANK 1 .
• Refer to INSTALLING THE CYLINDER HEAD COVER ON THE RIGHT .
• Refer to INSTALLING VANOS SOLENOID ACTUATOR, EXHAUST OF CYLINDER BANK 1 .
• Refer to INSTALLING THE VANOS SOLENOID ACTUATOR INTAKE OF CYLINDER BANK 1 .
• Refer to INSTALLING RIGHT HIGH PRESSURE PUMP .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING THE INJECTORS FOR THE CYLINDERS 1 TO 4 .
• Refer to INSTALLING THE RIGHT HIGH-PRESSURE RAIL .
• Refer to INSTALLING THE IGNITION COILS OF CYLINDERS 1 AND 5 .
• Refer to INSTALLING IGNITION COILS OF CYLINDER BANK 1 .
• Refer to PARTIALLY INSTALLING THE GUIDE TUBE FOR THE OIL DIPSTICK .
• Refer to INSTALLING FRONT HEAT SHIELD .
• Refer to INSERTING THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE EXHAUST TURBOCHARGER FOR THE CYLINDERS 1 TO 4 .
• Refer to INSTALLING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to INSTALLING CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to INSTALLING BOTH CHARGE AIR COOLERS .
• Refer to CONNECTING THE RIGHT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
• Refer to CONNECTING THE LEFT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
• Refer to CLOSING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to INSTALLING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT (CHARGE AIR COOLER) .
• Refer to SEALING OFF COOLANT FOR LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT THRUST FIELD .
• Refer to INSTALLING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
• Refer to INSTALLING THE FRONT LEFT BOTTOM WHEEL ARCH COVER .
• Refer to INSTALLING THE FRONT BOTTOM RIGHT WHEEL ARCH COVER .
• Refer to INSTALLING DRIVE BELT .
• Refer to INSTALLING FAN COWL .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING FRONT CROSS CONNECTION (FRONT-END STRUT REMOVED) .
• Refer to INSTALLING BOTH FRONT-END STRUTS .
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT CENTER .
• Refer to INSTALLING THE CATALYTIC CONVERTER FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE CATALYTIC CONVERTER FOR CYLINDERS 1 TO 4 .
• Refer to RELEASING THE HEAT SHIELD .
• Refer to INSTALLING THE CENTER COWL UPPER PART .
• Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to INSTALLING RIGHT HEAT SHIELD .
• Refer to INSTALLING LEFT HEAT SHIELD .
• Refer to INSTALLING HEAT SHIELD, TOP .
• Refer to INSTALLING THE RIGHT OXYGEN SENSOR MONITOR .
• Refer to INSTALLING THE LEFT OXYGEN SENSOR MONITOR .
• Refer to PARTIALLY INSTALLING THE RIGHT LAMBDA OXYGEN SENSOR .
• Refer to PARTIALLY INSTALLING THE LEFT LAMBDA OXYGEN SENSOR .
• Refer to INSTALLING THE RETAINING BRIDGE IN VEHICLES WITH A GASOLINE PARTICULATE FILTER .
• Refer to INSTALLING THE RETAINING BRIDGE .
• Refer to INSTALLING EXHAUST SYSTEM .
• Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
• Refer to IF INSTALLED: INSTALLING THE TORSION STRUT ON THE RIGHT, AND ON THE LEFT WHERE REQUIRED .
• Refer to INSTALLING THE REAR DIFFUSER .
• Refer to INSTALLING THE CONTROL UNIT BRACKET FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE COVER OF THE LEFT DME CONTROL UNIT .
• Refer to INSTALLING CONTROL UNIT HOLDER FOR CYLINDERS 1 TO 4 .
• Refer to INSTALLING THE COVER OF THE RIGHT DME CONTROL UNIT .
• Refer to CONNECTING ALL BATTERY GROUND LEADS .
• Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .