Group 15, Cylinder Head, Valve Drive

Information 

• The eyelets must not be inadvertently secured using aluminum screws! => Aluminum screws would break and the suspended engine would fall down! 

Fig 1: Identifying Valves, Naturally Aspirated Engines
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1. Intake valve
2. Valve-seat ring (intake)
3. Valve guide
4. Lower valve-spring plate (intake)
5. Valve stem seal
6. Set of valve springs (intake)
7. Upper valve-spring plate (intake)
8. Valve collet
9. Upper valve-spring plate (outlet)
10. Valve spring (one outlet valve spring)
11. Lower valve-spring plate (outlet)
12. Outlet valve
13. Valve-seat ring (outlet)

Fig 2: Identifying Valves, Turbo Engines
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1. Intake valve
2. Valve-seat ring (intake)
3. Valve guide
4. Lower valve-spring plate (intake)
5. Valve stem seal
6. Set of valve springs (intake)
7. Upper valve-spring plate (intake)
8. Valve collet
9. Upper valve-spring plate (outlet)
10. Valve spring (two outlet valve springs for turbo engines)
11. Lower valve-spring plate (outlet)
12. Valve-seat ring (outlet)
13. Outlet valve

Fig 3: Identifying Cylinder Head 1 To 4
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1. Cylinder head 1 to 4
2. Cylinder head gasket 1 to 4
3. Screw, M8 → Tightening torque: 23 Nm (17 ftlb.) 
4. Cover
5. Stopper
6. Stopper
7. Restrictor for valve-lift control → Tightening torque: 2 Nm (1.5 ftlb.) 
8. Cylinder-head screws => For tightening specifications, see Fig 5
9. Spark plug; when reinstalled → Tightening torque: 25 Nm (19 ftlb.)  ; if fitting new spark plugs → Tightening torque: 30 Nm (22 ftlb.) 

Fig 4: Identifying Cylinder Head 5 To 8
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1. Cylinder head 5 to 8
2. Screw plug → Tightening torque: 5 Nm (3.5 ftlb.) 
3. Spark plug; when reinstalled → Tightening torque: 25 Nm (19 ftlb.)  ; if fitting new spark plugs → Tightening torque: 30 Nm (22 ftlb.) 
4. Cylinder head gasket 5 to 8
5. Stopper
6. Restrictor for valve-lift control → Tightening torque: 2 Nm (1.5 ftlb.) 
7. Stopper
8. Cover
9. Cylinder-head screws => For tightening specifications, see Fig 5
   Fig 5: Tightening Sequence For Cylinder Head

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   1 to 10  - 1st Initial tightening → Tightening torque: 30 Nm (22 ftlb.)  ; 2nd Initial tightening → Tightening torque: 50 Nm (37 ftlb.)  ; loosen by 2 turns → Torque angle: 720°  ; 1st turn → Tightening torque: 30 Nm (22 ftlb.)  ; 2nd turn → Tightening torque: 30 Nm (22 ftlb.)  ; 3rd turn and final tightening (torque angle) → Torque angle: 110° 

Fig 6: Identifying Catches For Cylinders 1 To 4
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1. Screw plug → Tightening torque: 5 Nm (3.5 ftlb.) 
2. Threaded bolt => fit with medium-strength securing liquid. Visible length 17 mm (naturally aspirated engine) and 26 mm (turbo engine) (when screwed into cylinder head) 
3. Screw plug (instead of turbocharger oil line on naturally aspirated engine) → Tightening torque: 15 Nm (11 ftlb.) 
4. Sealing ring
5. Sealing ring
6. Screw plug for secondary air duct → Tightening torque: 15 Nm (11 ftlb.) 
7. Sealing ring
8. Screw plug → Tightening torque: 8 Nm (6 ftlb.) 
9. Stopper
10. Oil bearing surfaces on camshafts with engine oil

Fig 7: Identifying Catches For Cylinders 5 To 8
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1. Stopper
2. Screw plug → Tightening torque: 8 Nm (6 ftlb.) 
3. Sealing ring
4. Screw plug for secondary air duct → Tightening torque: 15 Nm (11 ftlb.) 
5. Sealing ring
6. Sealing ring
7. Screw plug (instead of turbocharger oil line on naturally aspirated engine) → Tightening torque: 15 Nm (11 ftlb.) 
8. Threaded bolt => fit with medium-strength securing liquid. Visible length 17 mm (naturally aspirated engine) and 26 mm (turbo engine) (when screwed into cylinder head) 
9. Oil bearing surfaces on camshafts with engine oil

Fig 8: Identifying Valve Cover For Seals, Cylinders 1 To 4
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1. Valve cover for cylinders 1 to 4 (align over bar ignition modules)
2. Oil cap
3. Aluminum screw  , M6 x 20; hall sender (phase sensor); always use new aluminum screws → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
4. Hall sender
5. Sealing ring
6. Valve cover seal
7. Valve cover seal, inner
8. Seal for hydraulic valve for camshaft control

Fig 9: Identifying Valve Cover For Seals, Cylinders 5 To 8
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1. Valve cover for cylinders 5 to 8 (align over bar ignition modules)
2. Hall sender
3. Aluminum screw  , M6 x 20; hall sender (phase sensor); always use new aluminum screws → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
4. Sealing ring
5. Valve cover seal
6. Valve cover seal, inner
7. Seal for hydraulic valve for camshaft control
   Fig 10: Tightening Sequence For Valve Cover For Cylinders 1 To 4

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   Fig 11: Tightening Sequence For Valve Cover For Cylinders 5 To 8

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Fig 12: Identifying Bar Ignition Modules And Valve Cover, Cylinders 1 To 4
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1. Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
2. Bar ignition module
3. Aluminum screw  , M6 x 20; bar ignition module; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
4. Aluminum screw  , M6 x 30; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
5. Cap
6. Steel screw  to eyelet → Tightening torque: 23 Nm (17 ftlb.) 
7. Eyelet
8. Aluminum screw  , M8 x 35 (on torque support); always use new aluminum screws; → Initial tightening: 10 Nm (7.5 ftlb.)  and → Final tightening: 90° Steel screw  to eyelet.

Fig 13: Identifying Bar Ignition Modules And Valve Cover, Cylinder Bank 5 To 8
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1. Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
2. Eyelet
3. Steel screw  to eyelet → Tightening torque: 23 Nm (17 ftlb.) 
4. Aluminum screw  , M6 x 30; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
5. Bar ignition module
6. Aluminum screw  , M6 x 20; bar ignition module; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
7. Sheetmetal holder
8. Cap

Fig 14: Identifying Camshafts, Cylinder Bank 1 To 4
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1. Camshaft (outlet)
2. Camshaft (intake)
3. Hydraulic valve for variable valve-lift control
4. Screw, M5 x 12 → Tightening torque: 6 Nm (4.5 ftlb.) 
5. Switching tappet (oil with engine oil)
6. Flat-base tappet (oil with engine oil)
7. Stopper
8. Mounting saddle 1 to 4
9. Stopper
10. Bearing locations (oil with engine oil)

1. Direction of travel

Fig 15: Identifying Camshaft Mount, Cylinder Bank 1 To 4
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1. Screw, M6 x 35 → Tightening torque: 13 Nm (9.5 ftlb.) 
2. Housing
3. Dowel sleeve
4. Housing (intake)
5. Housing (outlet)
6. Screw, M6 x 70 → Tightening torque: 13 Nm (9.5 ftlb.) 
7. Bearing surfaces (oil with engine oil)

1. Direction of travel

Fig 16: Identifying Camshafts, Cylinders 5 To 8
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1. Switching tappet (oil with engine oil)
2. Flat-base tappet (oil with engine oil)
3. Camshaft (intake)
4. Hydraulic valve for variable valve-lift control
5. Screw, M5 x 12 → Tightening torque: 6 Nm (4.5 ftlb.) 
6. Camshaft (outlet)
7. Stopper
8. Mounting saddle, cylinders 5 to 8
9. Stopper
10. Bearing surfaces (oil with engine oil)

1. Direction of travel

Fig 17: Identifying Camshaft Mount, Cylinders 5 To 8
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1. Dowel sleeves
2. Housing (intake)
3. Screw, M6 x 70 → Tightening torque: 13 Nm (9.5 ftlb.) 
4. Housing
5. Screw, M6 x 35 → Tightening torque: 13 Nm (9.5 ftlb.) 
6. Housing (outlet)
7. Bearing surfaces (oil with engine oil)

1. Direction of travel

Fig 18: Identifying Camshaft Control
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1. Screw, M12 Tighten fully after setting timing.  ; new screw must be used; Initial tightening, Step 1 → Tightening torque: 10 Nm (7.5 ftlb.)  ; Initial tightening, Step 2 → Tightening torque: 30 Nm (22 ftlb.)  ; Initial tightening, Step 3 (torque angle) → Torque angle: 100°  ; Loosening process, Step 1 → Torque angle: 90°  ; Loosening process, Step 2 → Torque angle: 360°  ; Final tightening, Step 1 → Tightening torque: 30 Nm (22 ftlb.)  ; Final tightening, Step 2 (torque angle) → Torque angle: 135° 
2. Camshaft controller with integrated hexagon for countering
3. Hydraulic valve for camshaft control
4. Screw, M5 x 12 → Tightening torque: 6 Nm (4.5 ftlb.) 

1. Cylinders 1 to 4
2. Cylinders 5 to 8

1. Outlet camshaft identification (green)
2. Intake camshaft identification (blue)
3. Intake camshaft identification (blue)
4. Outlet camshaft identification (green)

1. Cylinders 1 to 4
2. Cylinders 5 to 8

1. Outlet camshaft identification (green)
2. Intake camshaft identification (white)
3. Intake camshaft identification (white)
4. Outlet camshaft identification (green)

• All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads 

1. Matching number for cylinder head/intake camshaft housing, cylinder 1 (E1)
2. Matching number for cylinder head/intake camshaft housing, cylinder 2 (E2)
3. Matching number for cylinder head/intake camshaft housing, cylinder 3 (E3)
4. Matching number for cylinder head/intake camshaft housing, cylinder 4 (E4)
5. Matching number for cylinder head/outlet camshaft housing, cylinder 1 (A1)
6. Matching number for cylinder head/outlet camshaft housing, cylinder 2 (A2)
7. Matching number for cylinder head/outlet camshaft housing, cylinder 3 (A3)
8. Matching number for cylinder head/outlet camshaft housing, cylinder 4 (A4)

   arrow  - Direction of travel

1. Double-chain camshaft drive
2. Camshaft sprocket with integrated hexagon for countering
3. Screw, M12 Tighten fully after setting timing.  ; screw must be replaced; 1st turn → Tightening torque: 10 Nm (7.5 ftlb.)  ; 2nd turn → Tightening torque: 50 Nm (37 ftlb.)  ; Final tightening (torque angle) → Torque angle: 90° 
4. Deflector rail
5. Screw, M8 x 35 → Tightening torque: 32 Nm (24 ftlb.) 
6. Camshaft-to-camshaft guide pad

1. Direction of travel

1. Crankshaft sprocket
2. Friction plates/diamond washers; reusable 
3. Oil pump drive chain
4. Drive in spring wedge with a plastic hammer 
5. Oil pump

1. Threaded peg → Tightening torque: 35 Nm (26 ftlb.) 
2. Threaded peg → Tightening torque: 20 Nm (15 ftlb.) 
3. Guide rail
4. Tensioning rail
5. Chain tensioner with sealing ring; always use new sealing ring → Tightening torque: 60 Nm (44 ftlb.) 
6. Pin (for locking the oil-pump tensioning rail)

1. Direction of travel

1. Timing-case cover
2. Timing-case cover seal, outer right (fill openings with sealant, see  6)
3. Timing-case cover seal, inner
4. Timing-case cover seal, rib
5. Timing-case cover seal, outer left (fill openings with sealant, see 6)
6. Sealant application on timing chain housing; Loctite 5900 (000.043.204.35 status 10/08)

1. When timing-case cover is fitted, apply sealant to joint before fitting valve covers
2. When timing-case cover is fitted, apply sealant to joint before fitting valve covers

1. When timing-case cover is fitted, apply sealant to joint before fitting valve covers

   20 mm  - Length of sealant applied to joint

1. Aluminum screw  , M6 x 30; timing-case cover to crankcase and cylinder head; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
2. Aluminum screw  M6 x 55; inner timing-case cover to upper part of crankcase and cylinder head; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90°  ; Outer timing-case cover to cylinder head → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
3. Aluminum screw  , M8 x 55; timing-case cover (location of chain tensioner) to upper part of crankcase and cylinder head; always use new aluminum screws; → Initial tightening: 10 Nm (7.5 ftlb.)  and → Final tightening: 90° 
4. The timing-case cover must be level with the lower part of the crankcase (use steel rule or dial gauge)

1. Joint flange (oil sealing lip with engine oil); align with sleeve or vibration balancer
2. Aluminum screw  , M6 x 20; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
3. Aluminum screw  , M6 x 55; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.)  and → Final tightening: 90° 
4. Sealing ring; always replace
5. Chain tensioner → Tightening torque: 60 Nm (44 ftlb.)