Installing Valve Tappets Of Cylinder Bank 1 - 3

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Check guide for damage. Refer to CHECKING GUIDE FOR VALVE TAPPETS .
Fit guide. Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque: 10 Nm (7.5 ft.lb)
Lightly oil the valve tappets and fit in the guide.
Lay the complete unit, camshafts with chain and tensioning element, into the cylinder head. The groove or tab of the camshaft position sensor cover must face outward in installed position. If the allocation should be uncertain, e.g. chain jumped over, reallocation is necessary. Refer to COMPLETING CAMSHAFTS .

Fig 1: Locating Groove Or Tab Of Camshaft Position Sensor Cover
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Fasten special tool, holding-down device 9611, with auxiliary screws M6 x 45.
Fit special tool, holding-down device 9624, on the cylinder head using a hexagon-head bolt M8 x 30.

Fig 2: Installing Hold-Down Device 9624 On The Cylinder Head
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Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Oil bearing surface. Fit bearing saddles in the correct position and tighten evenly. Tightening torque: 10 Nm (7.5 ft.lb)

Fig 3: Locating Bearing Saddle Identification Numbers
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E = Bearing saddle for inlet camshaft A = Bearing saddle for exhaust camshaft
Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque: 10 Nm (7.5 ft.lb).
Unscrew tensioning screw, special tool 9632, from the tensioning element.
Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.
Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolt M6 x 15 (10.9). Tighten hexagon-head bolt by hand only.
Unscrew chain tensioner (fitted on the crankcase half of cylinder bank 4-6) and fasten auxiliary chain tensioner (special tool 9599). Fit auxiliary chain tensioner without sealing ring and fasten on the crankcase only hand-tight. The mechanical auxiliary chain tensioners must be installed with the correct pre-tension when the valve timing is adjusted or checked. The necessary pre-tension force has been reached when the measuring pin is flush with the face surface of the thrust screw. Turn the screw if necessary.

Fig 4: Unscrewing Chain Tensioner On The Crankcase Half Of Cylinder Bank 4-6
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Fit auxiliary chain tensioner on cylinder head 1-3 and adjust pre-tension force (refer to step 12).

Fig 5: Fitting Auxiliary Chain Tensioner On Cylinder Head 1-3
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Fit cylinder-head cover. Remove holding-down device 9611. Clean sealing surface of the cylinder head and cylinder-head cover very carefully. Apply bead of silicone on the cylinder-head cover. Refer to SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER) .

Fig 6: Applying Bead Of Silicone On The Cylinder-Head Cover
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Carefully place the cylinder-head cover in the correct position so that the sealing bead is not damaged. Screw two studs or centering pins into the corners of the cylinder head as centering aids. Tightening torque: 13 Nm (10.0 ft.lb)

Immediately remove silicone material emerging in the area of the camshaft closure cap.
For the subsequent adjustment work on the camshaft, the pulley must be fixed at bore 1 OT (TDC) with the fixing pin (special tool 9595).

Fig 7: Fixing Pulley At Bore 1 (TDC) With The Fixing Pin (Special Tool 9595)
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Fasten blocking device (special tool 9612) on the cylinder head.

Fig 8: Fastening Blocking Device (Special Tool 9612) On The Cylinder Head
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1. Fastening screw with star knob on the cylinder-head lug. Pull back centering piece (B) and sword bolt (C) when tightening. See Fig 9.
2. Centering piece in groove of the exhaust camshaft. Pull back sword bolt (C) when tightening. See Fig 9.
3. Sword bolt
Fig 9: Installing Centering Piece On Camshafts
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Allocate camshafts; to do this, turn the pre-tensioned Centre piece accordingly until the sword bolt can be fixed in the bearing bore.

Fig 10: Identifying Sword Bolt
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Fasten sprocket wheel. Tightening torque: 14 Nm (10.5 ft.lb)
Remove blocking device.
NOTE:
- The auxiliary chain tensioners must remain fitted on cylinder bank 4 - 6 for the subsequent assembly work.
Fit oil extraction pump.
NOTE:
- The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation
position or direction of rotation must be correct.

Installation position of oil extraction pump at cylinder head 1 - 3 (flywheel side): The arrow for the direction of rotation or the marking "1 - 3" must face the crankcase. Fit oil extraction pump. Use new sealing ring and new micro-encapsulated hexagon socket head screws.

Tightening torque: 10 Nm (7.5 ft.lb).

Fig 11: Identifying Installation Position Of Oil Extraction Pump At Cylinder Head
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Fit camshaft closure cap dry.
Fit closure cap on tensioning element (VarioCam). Tightening torque: 10 Nm (7.5 ft.lb).