Disassembling and assembling cylinder head, right

Preliminary work 

• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVING THE COVER PANEL OF THE MASTER DME CONTROL UNIT .
• Refer to REMOVING THE COVER PANEL OF THE SLAVE DME CONTROL DEVICE .
• Refer to REMOVING THE ACOUSTIC COVER .
• Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT .
• Removing the cover of the rear right engine compartment.

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  • Loosen the lock (1)
  • Remove the cover (2).

  Covering the vehicle battery 

  WARNING: Unprotected battery terminals. Risk of short circuits! Risk of fire!

  • Cover the vehicle battery

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  NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
  • Cover the vehicle battery with the special tool 2 452 007  as shown.
• 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 REMOVING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
• Refer to REMOVING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
• Refer to RELEASING LEFT FRONT-END STRUT .
• Refer to RELEASING THE RIGHT FRONT-END STRUT .
• Refer to REMOVING FRONT CROSS CONNECTION .
• Refer to REMOVING LEFT INTAKE SILENCER HOUSING .
• Refer to REMOVING RIGHT INTAKE SILENCER HOUSING .
• Refer to REMOVING THE REAR TOP CROSS CONNECTION .
• Refer to REMOVING FAN COWL WITH ELECTRIC MOTOR .
• Refer to REMOVING THE STIFFENING PLATE .
• Refer to REMOVING FRONT RIGHT WHEEL .
• Refer to REMOVING THE FRONT RIGHT LOWER WHEEL ARCH COVER .
• Refer to DRAINING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to REMOVING DRIVE BELT .
• Refer to REMOVING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
• Refer to DRAINING THE COOLANT FROM THE COOLANT PUMPS .
• Refer to REMOVING LEFT AND RIGHT CHARGE AIR COOLER .
• Refer to REMOVING RIGHT TANK VENT VALVE .
• Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 2 .
• Refer to REMOVING FUEL DELIVERY LINE .
• Refer to REMOVING THE ELECTRIC COOLANT PUMP WITH THE HOLDER .
• Refer to REMOVING THE ALTERNATOR .
• Refer to REMOVING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
• Refer to REMOVING LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
• Refer to REMOVING HOLDER OF DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
• Refer to REMOVING COOLANT EXPANSION TANK .
• Refer to REMOVING EXPANSION TANKS FOR THE CHARGE AIR COOLERS .
• Refer to LIFTING THE HEAT SHIELD AT THE SIDE .
• Refer to REMOVING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 1 .
• Refer to REMOVING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
• Removing conduit from bank 1.

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  • Loosen screws (1).
  • Slide conduit (2) downwards.
• Removing the tank ventilation line of cylinder bank 1 partially.

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  • Press the tank vent line (2) on the catch (1) and unlock.
  • Disconnect the tank vent line (2).
  • Fold the tank vent line (2) to the side
• Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to REMOVING ENGINE VENTILATION LINE OF CYLINDER BANK 1 .
• Refer to REMOVING THE WIRING HARNESS FROM THE CYLINDER BANK 2 .
• Refer to REMOVING UPPER HEAT SHIELD .
• Refer to REMOVING UPPER CATALYTIC CONVERTER NEAR ENGINE FROM CYLINDER BANK 1 .
• Refer to REMOVING THE CATALYTIC CONVERTER NEAR THE ENGINE AT TOPPING OF CYLINDER BANK 2 .
• Refer to REMOVING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to REMOVING THE CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to REMOVING LEFT MOUNT .
• Refer to REMOVING RIGHT MOUNT .
• Refer to REMOVING THE LEFT AND RIGHT EXHAUST TURBOCHARGER .
• Refer to REMOVING HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 1 TO 4 .
• Refer to REMOVING HEAT SHIELD OF CYLINDER HEAD COVER OF CYLINDERS 5 TO 8 .
• Refer to REMOVING BOTH EXHAUST MANIFOLDS .
• Refer to REMOVING FRONT HEAT SHIELD .
• Refer to REMOVING HEAT SHIELD AT BOTTOM .
• Refer to REMOVING VACUUM PUMP .
• Refer to REMOVING RIGHT CYLINDER HEAD COVER .
• Refer to REMOVING THE ELECTRIC COOLANT PUMP WITH THE HOLDER .
• Refer to REMOVING THE SEALING CAP ON THE CYLINDER HEAD OF THE CYLINDER BANK 1 .
• Refer to REMOVING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
• Refer to MOVING THE CRANKSHAFT INTO THE INSTALLATION POSITION OF CYLINDER BANK 1 .
• 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 .
• Preloading the timing chain of cylinder bank 1.
  CAUTION: RISK OF DAMAGE 

  Damage to timing chain or timing chain drive.

  Turning the engine without chain tensioner or special tool can result in damage to the timing chain and timing chain drive.

  • Always turn the engine with the chain tensioner or the special tool.

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  • Hand-tighten the bolts (1).
  • Pre-tension timing chain on special tool 2 249 162  at hexagon screw (2) with special tool 0 496 778 (00 9 460)  to 0.6 Nm.
  TIGHTENING TORQUES
  
  

  Preload timing chain
  tightening torque	0.6 Nm

• Refer to SECURING THE ENGINE IN INSTALLATION POSITION AT CYLINDER 1 .
• Refer to INSTALLING THE SPECIAL TOOL TO SECURING THE CAMSHAFTS OF CYLINDER BANK 1 .
• Refer to REMOVING BOTH RIGHT VANOS ADJUSTERS .
• Refer to REMOVING SPECIAL TOOL FOR FIXING CAMSHAFTS ON BANK 1 .
• Refer to REMOVING RIGHT CYLINDER HEAD .

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.

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  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

• 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).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  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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• Gradually release the screws of the guide bearing in the sequence (10) to (1) in half turns.
• Feed the guide bearing shell of the exhaust camshaft out and remove it.
• Feed out and 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.

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  Twist camshaft if necessary.

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 

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

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

Replacing the valve stem seals 

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• 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 

• 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)  .

Eccentric shaft bearing brackets
Screw M6	Tightening torque	10 Nm

Releasing tension on special tool 119000 

• 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 

• 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 

• 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.
• 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	Snug torque	10 Nm
  	Tightening torque	10.5 Nm

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• Tighten down screws (4)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake/exhaust camshaft
  M6	Snug torque	10 Nm
  	Tightening torque	10.5 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 

• 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)  .

• 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. 

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• 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	10 Nm

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• The special tool 2 249 160 (2)  must be pre-tensioned.
• 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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• Maneuver and install the exhaust camshaft.
• Maneuver the guide bearing shells of the exhaust camshafts (A1) to (A4) and install them.

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  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Ensure that the ground surfaces of camshafts (2) point up.
• Make sure that the rounded surfaces (1) point downwards to the cylinder head.
• Check the camshaft positions of bank 1.
• The cams (1) must be in the position shown.
• Increment wheels (2) must form a straight line to the exhaust camshaft bearing cap and the intake camshaft bearing cap.
• Gradually bring the screws of the guide bearing in position in the sequence (1) to (10) in halfturns.
• Turn the screws in the order from (1) to (10) to tighten to the snug torque.
  Fig 2: Exhaust Camshaft Screws Tightening Sequence

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  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake/exhaust camshaft
  M6	Snug torque	10 Nm
  	Tightening torque	10.5 Nm

• Tighten the screws in the sequence (1) to (10) with the tightening torque.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake/exhaust camshaft
  M6	Snug torque	10 Nm
  	Tightening torque	10.5 Nm

• Maneuver the roller tappet (1) in the high-pressure pump bracket (2) and install it.

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

• 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) 

• 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

  400g, Cartridge

  83192160340

  Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Installing right intake plenum (cylinder head removed) 

• Replace the seal (4)  .

  Parts:  Seal

  Courtesy of BMW OF NORTH AMERICA, INC.

  Courtesy of BMW OF NORTH AMERICA, INC.

• 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)  .

  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)  .

Intake plenum
M8 screw	Tightening torque	21.4 Nm

Install engine mounting bracket of bank 1 

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

Engine suspension element
M8x22 screw	Tightening torque	20 Nm

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

Insert spark plug (1) into special tool 

• 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.

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• Tighten spark plugs (1)  with a torque wrench, special tool 0 496 065 (12 1 230) and extension with joint.

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Spark plugs
M12x1.25	Tightening torque	23 Nm

Installing venting connector of bank 1 

• Replace the venting connector (1)  .
• Parts:  Venting connector
• Tighten the venting connector (1). 

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

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Follow-up work 

• Refer to INSTALLING RIGHT CYLINDER HEAD .
• Refer to INSTALLING BOTH VANOS ADJUSTERS (CYLINDER HEAD DISASSEMBLY, BANK 1) .
• Refer to INSTALLING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
• Refer to INSTALLING ELECTRIC COOLANT PUMP WITH HOLDER .
• Refer to INSTALLING THE CYLINDER HEAD COVER ON THE RIGHT .
• Refer to INSTALLING THE VACUUM PUMP .
• Refer to INSTALLING HEAT SHIELD ON THE BOTTOM .
• Refer to INSTALLING FRONT HEAT SHIELD .
• Refer to INSTALLING BOTH EXHAUST MANIFOLDS .
• Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 1 TO 4 .
• Refer to INSTALLING LEFT AND RIGHT EXHAUST TURBOCHARGERS .
• Refer to MOUNTING FIXTURE ON THE RIGHT .
• Refer to INSTALLING LEFT MOUNT .
• Refer to INSTALLING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to INSTALLING CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to INSTALLING CATALYTIC CONVERTER NEAR THE ENGINE ABOVE CYLINDER BANK 1 .
• Refer to INSTALLING UPPER CATALYTIC CONVERTER NEAR ENGINE FOR BANK 2 .
• Refer to INSTALLING HEAT SHIELD, TOP .
• Installing conduit on bank 2.

  Courtesy of BMW OF NORTH AMERICA, INC.

  • Clip the wiring harness (2) into the clamps (1).

  Courtesy of BMW OF NORTH AMERICA, INC.

  • Position the wiring harness.
  • Tighten down screws (1).
    TIGHTENING TORQUES
    
    

    Cable duct
    M6x16 screw	Tightening torque	10Nm

• Refer to INSTALLING ENGINE VENTILATION LINE OF CYLINDER BANK 1 .
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE TANK VENTILATION LINE OF CYLINDER BANK 1 PARTIALLY .
• Installing cable duct at cylinder bank 1.

  Courtesy of BMW OF NORTH AMERICA, INC.

  • Position the conduit (2).
  • Tighten the screws (1).
  TIGHTENING TORQUES
  
  

  Cable duct
  M6x16 screw	Tightening torque	10Nm

• Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 1 .
• Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
• Refer to CHECKING THE POSITION OF THE HEAT SHIELD .
• Refer to INSTALLING THE EXPANSION TANK FOR THE CHARGE AIR COOLER .
• Refer to INSTALLING COOLANT EXPANSION TANK .
• Refer to INSTALLING HOLDER OF THE DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
• Refer to INSTALLING ALTERNATOR .
• Refer to INSTALLING ELECTRIC COOLANT PUMP WITH HOLDER .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING HOLDER WITH THE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 2 .
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE RIGHT TANK VENT VALVE .
• Refer to INSTALLING THE CHARGE AIR COOLER ON THE LEFT AND RIGHT .
• Refer to CLOSING THE COOLANT PUMPS .
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
• Refer to INSTALLING DRIVE BELT .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to INSTALLING THE FRONT RIGHT WHEEL .
• Refer to INSTALLING FAN COWL WITH ELECTRIC MOTOR .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING RIGHT INTAKE SILENCER HOUSING .
• Refer to INSTALLING LEFT INTAKE SILENCER HOUSING .
• Refer to INSTALLING FRONT CROSS CONNECTION .
• Refer to TIGHTENING THE LEFT FRONT-END STRUT .
• Refer to TIGHTENING THE FRONT-END STRUT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
• 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 ACOUSTIC COVER .
• Refer to INSTALLING THE COVER PANEL OF THE SLAVE DME CONTROL UNIT .
• Refer to INSTALLING THE COVER PANEL OF THE MASTER DME CONTROL UNIT .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
• Refer to CHECKING ENGINE OIL LEVEL .