15 Cylinder Head Valve Train
Valves, naturally aspirated engines
| 1 | Inlet valve |
| 2 | Intake valve seat ring (intake) |
| 3 | Valve guide |
| 4 | Lower valve spring seat (intake) |
| 5 | Valve-stem seal |
| 6 | Set of valve springs (intake) |
| 7 | Upper valve spring seat (intake) |
| 8 | Valve collet |
| 9 | Upper valve spring seat (exhaust) |
| 10 | Valve spring (one exhaust valve spring) |
| 11 | Lower valve spring seat (exhaust) |
| 12 | Exhaust valve |
| 13 | Valve seat ring (exhaust) |
Valves, turbo engines
| 1 | Inlet valve |
| 2 | Intake valve seat ring (intake) |
| 3 | Valve guide |
| 4 | Lower valve spring seat (intake) |
| 5 | Valve-stem seal |
| 6 | Set of valve springs (intake) |
| 7 | Upper valve spring seat (intake) |
| 8 | Valve collet |
| 9 | Upper valve spring seat (exhaust) |
| 10 | Valve spring (two exhaust valve springs for turbo engines) |
| 11 | Lower valve spring seat (exhaust) |
| 12 | Valve seat ring (exhaust) |
| 13 | Exhaust valve |
Cylinder head 1 to 4
| 1 | Cylinder head 1 to 4 |
| 2 | Cylinder-head gasket 1 to 4 |
| 3 | Screw M8 > Tightening torque 23 Nm (17 ftlb.) |
| 4 | Lid |
| 5 | Stopper |
| 6 | Stopper |
| 7 | Restrictor for valve lift adjustment > Tightening torque 2 Nm (1.5 ftlb.) |
| 8 | Cylinder head screws => For tightening specifications, see Tightening sequence for cylinder head |
| 9 | Spark plug; > Tightening torque 25 Nm (18.4 ftlb.)
for re-installation; > Tightening torque 30 Nm (22.1 ftlb.)
for new installation Electrode gap of spark plug FGR5NQE >, check value 1.6 mm +/- 0.05 mm Electrode gap of spark plug FR6NPP >, check value 0.7 mm + 0.1 mm |
Cylinder head 5 to 8
| 1 | Cylinder head 5 to 8 |
| 2 | Screw plug > Tightening torque 5 Nm (3.7 ftlb.) |
| 3 | Spark plug; > Tightening torque 25 Nm (18.4 ftlb.) for re-installation; > Tightening torque 30 Nm (22.1 ftlb.) for new installation |
| 4 | Cylinder-head gasket 5 to 8 |
| 5 | Stoppers |
| 6 | Restrictor for valve lift adjustment > Tightening torque 2 Nm (1.5 ftlb.) |
| 7 | Stoppers |
| 8 | Lid |
| 9 | Cylinder head screws => For tightening specifications, see Tightening sequence for cylinder head |
Tightening sequence for cylinder head
| 1 to 10 | 1st Adjustment torque > Tightening torque 30 Nm (22.1 ftlb.) ; 2. Adjustment torque > Tightening torque 50 Nm (36.9 ftlb.) ; 2 Loosen turns > Turning anale 720° ; 1. Passage > Tightening torque 30 Nm (22.1 ftlb.) ; 2. Passage > Tightening torque 30 Nm (22.1 ftlb.) ; 3. Passage and final tightening (torque angle) > Torque angle 110° |
Cylinder 1 to 4 closures
| 1 | Screw plug > Tightening torque 5 Nm (3.7 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 (on naturally aspirated engine instead of on turbocharger oil pipe) > Tightening torque 15 Nm (11.1 ftlb.) |
| 4 | Sealing ring |
| 5 | Sealing ring |
| 6 | Screw plug for secondary-air duct > Tightening torque 15 Nm (11.1 ftlb.) |
| 7 | Sealing ring |
| 8 | Screw plug > Tightening torque 8 Nm (5.9 ftlb.) |
| 9 | Stopper |
| 10 | Oil bearing surfaces on camshafts with engine oil |
Catches for cylinders 5 to 8
| 1 | Stopper |
| 2 | Screw plug > Tightening torque 8 Nm (5.9 ftlb.) |
| 3 | Sealing ring |
| 4 | Screw plug for secondary air duct > Tightening torque 15 Nm (11.1 ftlb.) |
| 5 | Sealing ring |
| 6 | Sealing ring |
| 7 | Screw plug (on the aspirator instead of the turbocharger oil pipe) > Tightening torque 15 Nm (11.1 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 |
Valve cover gaskets, cylinders 1 to 4
| 1 | Valve cover for cylinders 1 to 4 (align over rod ignition modules) |
| 2 | Oil cap |
| 3 | Aluminium screw M6 x 20; Hall sender (phase encoder); always renew aluminium screws > Initial torque 4 Nm (3 ftlb.) and > final torque 90° |
| 4 | Hall sender |
| 5 | Sealing ring |
| 6 | Cylinder head cover gasket |
| 7 | Cylinder head cover gasket, inner |
| 8 | Seal for hydraulic valve for camshaft control |
Valve cover cylinder seals 5 to 8
| 1 | Valve cover for cylinders 5 to 8 (align over rod ignition modules) |
| 2 | Hall sender |
| 3 | Aluminium screw M6 x 20; Hall sender (phase encoder); always renew aluminium screws > Initial torque 4 Nm (3 ftlb.) and > Final torque 90° |
| 4 | Sealing ring |
| 5 | Cylinder head cover gasket |
| 6 | Cylinder head cover gasket inner |
| 7 | Seal for hydraulic valve for camshaft control |
Tightening sequence for valve cover for cylinders 1 to 4
Tightening sequence for valve cover for cylinders 5 to 8
Rod ignition modules and valve cover for cylinders 1 to 4
| 1 | Valve cover for cylinder bank 1 to 4 (align over rod ignition modules) |
| 2 | Rod ignition module |
| 3 | Aluminium screw M6 x 20; rod ignition module; always renew aluminium screws; > initial torque 4 Nm (3 ftlb.) and > final torque 90° |
| 4 | Aluminium screw M6 x 30; Rod ignition module; always renew aluminium screws; > Initial torque 4 Nm (3 ftlb.) and > final torque 90° |
| 5 | Cover plate |
| 6 | Steel screw on eyelet > Tightening torque 23 Nm (17 ftlb.) |
| 7 | Eyelet |
| 8 | Aluminium screw
M8 x 35 (to torque support); always renew aluminium screws; > Initial torque 10 Nm (7.4 ftlb.)
> and > final torque 90° Steel screw
to lifting eye! Information
|
rod ignition modules and valve covers, cylinder bank 5 to 8
| 1 | Valve cover for cylinder bank 5 to 8 (align over rod ignition modules) |
| 2 | Eyelet |
| 3 | Steel screw on eyelet > Tightening torque 23 Nm (17 ftlb.) Information
|
| 4 | Aluminium screw M6 x 30; rod ignition module; always renew aluminium screws; > initial torque 4 Nm (3 ftlb.) and > final torque 90° |
| 5 | Rod ignition module |
| 6 | Aluminium screw M6 x 20; rod ignition module; always renew aluminium screws; > initial torque 4 Nm (3 ftlb.) and > final torque 90° |
| 7 | Sheetmetal holder |
| 8 | Cover plate |
Camshafts, cylinder bank 1 to 4
| 1 | Camshaft (exhaust) |
| 2 | Camshaft (intake) |
| 3 | Hydraulic valve for variable valve lift control (VVS) |
| 4 | Screw M5 x 12 > Tightening torque 6 Nm (4.4 ftlb.) |
| 5 | Switching tappet (oil with engine oil) |
| 6 | Bucket tappet (oil with engine oil) |
| 7 | Stopper |
| 8 | Mounting saddle 1 to 4 |
| 9 | Stopper |
| 10 | Bearing locations (oil with engine oil) |
| A | Direction of travel |
Camshaft mount, cylinder bank 1 to 4
| 1 | Screw M6 x 35 > Tightening torque 13 Nm (9.6 ftlb.) |
| 2 | Housing |
| 3 | Dowel sleeve |
| 4 | Housing (intake) |
| 5 | Housing (exhaust) |
| 6 | Screw M6 x 70 > Tightening torque 13 Nm (9.6 ftlb.) |
| 7 | Bearing surfaces (oil with engine oil) |
| A | Direction of travel |
Camshafts, cylinders 5 to 8
| 1 | Switching tappet (oil with engine oil) |
| 2 | Bucket 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 (4.4 ftlb.) |
| 6 | Camshaft (exhaust) |
| 7 | Stopper |
| 8 | Mounting saddle, cylinders 5 to 8 |
| 9 | Stopper |
| 10 | Bearing surfaces (oil with engine oil) |
| A | Direction of travel |
Camshaft mount, cylinders 5 to 8
| 1 | Dowel sleeves |
| 2 | Housing (intake) |
| 3 | Screw M6 x 70 > Tightening torque 13 Nm (9.6 ftlb.) |
| 4 | Housing |
| 5 | Screw M6 x 35 > Tightening torque 13 Nm (9.6 ftlb.) |
| 6 | Housing (exhaust) |
| 7 | Bearing surfaces (oil with engine oil) |
| A | Direction of travel |
Camshaft adjustment
| 1 | Screw, M12 Tighten fully after setting valve timing! ; Screw must be renewed; pre-tightening 1st step > Tightening torque 10 Nm (7.4 ftlb.) ; initial tightening 2nd step > Tightening torque 30 Nm (22.1 ftlb.) ; initial tightening 3rd step (torque angle) > Torque angle 100° ; loosening process 1st step > Turning angle 90° ; loosening process 2nd step > Torque angle 360° ; final tightening 1st step > Tightening torque 30 Nm (22.1 ftlb.) ; initial tightening 2nd step (torque angle) > Torque angle 135° |
| 2 | Camshaft controller with integrated hexagon for countering |
| 3 | Hydraulic valve for camshaft adjustment [NVS] |
| 4 | Screw M5 x 12 > Tightening torque 6 Nm (4.4 ftlb.) |
Camshaft identification on V8 turbo engine
| A | Cylinders 1 to 4 |
| B | Cylinders 5 to 8 |
| 1 | Exhaust camshaft identification (green) |
| 2 | Intake camshaft identification (blue) |
| 3 | Intake camshaft identification (blue) |
| 4 | Exhaust camshaft identification (green) |
Camshaft identification on V8 naturally aspirated engine
| A | Cylinders 1 to 4 |
| B | Cylinders 5 to 8 |
| 1 | Exhaust camshaft identification (green) |
| 2 | Intake camshaft identification (white) |
| 3 | Intake camshaft identification (white) |
| 4 | Exhaust camshaft identification (green) |
Camshaft bearing cover identification
| 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/bearing cover intake camshaft, cylinder 2 (E2) |
| 3 | Matching number for cylinder head/bearing cover intake camshaft, cylinder 3 (E3) |
| 4 | Matching number for cylinder head/bearing cover intake camshaft, cylinder 4 (E4) |
| 5 | Matching number for cylinder head/bearing cover exhaust camshaft camshaft, cylinder 1 (A1) |
| 6 | Matching number for cylinder head/bearing cover exhaust camshaft camshaft, cylinder 2 (A2) |
| 7 | Matching number for cylinder head/bearing cover exhaust camshaft camshaft, cylinder 3 (A3) |
| 8 | Matching number for cylinder head/bearing cover exhaust camshaft camshaft, cylinder 4 (A4) |
| Arrow | Direction of travel |
Timing chain and sprockets
| 1 | Double-chain camshaft drive |
| 2 | Camshaft sprocket with integrated hexagon for countering |
| 3 | Screw, M12 Tighten fully after setting valve timing !; screw must be renewed; 1st pass > Tightening torque 10 Nm (7.4 ftlb.) ; 2nd pass > Tightening torque 50 Nm (36.9 ftlb.) ; final tightening (torque anale) > torque angle 90° |
| 4 | Deflector rail |
| 5 | Screw M8 x 35 > Tightening torque 32 Nm (23.6 ftlb.) |
| 6 | Camshaft-to-camshaft guide pad |
| A | Direction of travel |
Oil pump chain drive
| 1 | Crankshaft sprocket |
| 2 | Friction plates/diamond washers can be re-used |
| 3 | Oil pump drive chain |
| 4 | Drive in spring wedge with a plastic hammer |
| 5 | Oil pump |
Timing chain and chain guide
| 1 | Screw-on peg > Tightening torque 35 Nm (25.8 ftlb.) |
| 2 | Screw-on peg > Tightening torque 20 Nm (14.8 ftlb.) |
| 3 | Guide rail |
| 4 | Tensioning rail |
| 5 | Chain tensioner with sealing ring; always replace sealing ring > Tightening torque 60 Nm (44.3 ftlb.) |
| 6 | Pin (for locking the oil pump tension rail) |
| A | Direction of travel |
Chain housing cover seals
| 1 | Chain housing cover |
| 2 | Chain housing cover seal, outer right (filling openings with sealant, see 6) |
| 3 | Inner chain housing cover seal |
| 4 | Chain housing cover rib seal |
| 5 | Chain housing cover seal, outer left (filling openings with sealant, see 6) |
| 6 | Applying sealant to control chain housing; Loctite 5900 (000.043.204.35 status 10/08) |
Applying sealant (filling openings in metal seal)
| 1 | When chain housing cover is fitted, apply sealant to joint before fitting valve covers |
| 2 | When chain housing cover is fitted, apply sealant to joint before fitting valve covers |
Applying sealant before fitting valve covers
| 1 | When chain housing cover is fitted, apply sealant to joint before fitting valve covers |
| 20 mm | Length of sealant applied to joint Information In case of repair, two aluminium screws must be changed to steel screws -15 and 30- with aluminium washers -Arrows- . |
> Refer to 153300 Symptom Engine - Loose/broken screws and/or oil leaks in chain housing cover and/or camshaft adjuster cover (SY 210/21)
Steel screw with aluminium washer
Tightening specifications for chain housing cover
| 1-30 | Tightening sequence |
| 1-4 | Aluminium screw M6 x 55 |
| 5 + 6 | Aluminium screw M8 x 55 |
| 7-12 | Aluminium screw M6 x 30 |
| 13 + 14 | Aluminium screw M6 x 55 |
| 15 | Steel screw M6 x 30 with aluminium washer 6.4 x 14 x 3 mm |
| 14-28 | Aluminium screw M6 x 30 |
| 29 | Aluminium screw M6 x 55 |
| 30 | Steel screw M6 x 30 with aluminium washer 6.4 x 14 x 3 mm |
| 1-4 + 7-14 + 16-29 | Aluminium screw M6 > Initial tightening 4 Nm (3 ftlb.) > Final tightening + 90° > Minimum torque angle + 50° > Maximum Torque angle + 95° > Lower torque limit 5.2 Nm (3.8 ftlb.). > Upper torque limit 9 Nm (6.6 ftlb.) |
| 5 + 6 | Aluminium screw M8 > Initial tightening 10 Nm (7.4 ftlb.) > Final tightening + 90° |
| 15 + 30 | Steel screw M6 x 30 > Tightening torque 10 Nm (7.4 ftlb.) |
| Location | Description | Type | Basic value | Tolerance |
|---|---|---|---|---|
| Maximum offset of chain housing cover | Length | 0.1 mm |
Measuring offset
Chain tensioner, joint flange
| 1 | Joint flange (oil sealing lip with engine oil); align with sleeve or vibration balancer/replace |
| 2 | Aluminium screw M6 x 20; Always renew aluminium screws; > Pre-tensioning 4 Nm (3 ftlb.) and > Final tensioning 90° |
| 3 | Aluminium screw M6 x 55; Always renew aluminium screws; > Pre-tensioning 4 Nm (3 ftlb.) > and > final tensioning 90° |
| 4 | Sealing ring; always replace |
| 5 | Chain tensioner > Tightening torque 60 Nm (44.3 ftlb.) |
17 - Lubrication
Oil/water heat exchanger, oil filter for 2WD
| 1 | Oil guide housing |
| 2 | Oil-filter cover > Tightening torque 25 Nm (19 ftlb.) |
| 3 | Oil filter |
| 4 | Oil-filter gasket |
| 5 | Oil duct adapter (cannot be replaced) |
| 6 | Heat exchanger seal |
| 7 | Oil/water heat exchanger |
| 8 | Screw, M6 x 20; self-tapping screws ex-works; metric screws can also be used > Tightening torque 10 Nm (7.5 ftlb.) |
Oil/water heat exchanger, oil filter, 4WD
| 1 | Oil guide housing |
| 2 | Oil-filter cover > Tightening torque 25 Nm (19 ftlb.) |
| 3 | Oil filter |
| 4 | Oil-filter gasket |
| 5 | Oil duct adapter (cannot be replaced) |
| 6 | Heat exchanger seal |
| 7 | Oil/water heat exchanger |
| 8 | Screw, M6 x 20; self-tapping screws ex-works; metric screws can also be used > Tightening torque 10 Nm (7.5 ftlb.) |
Applying sealant to oil guide housing
| 1 | Seal application (geometry, 1-mm bead of sealant) |
| 2 | Sealant application - Doboseal 224N (999.915.573.43, status 09/08) |
| A | Direction of travel |
Applying sealant to oil guide housing (4WD)
| 1 | Sealant application (geometry, sealing bead 1 mm); Doboseal 224N (999.915.573.43, status 09/08) |
Oil guide housing with accessories
| 1 | Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.) |
| 2 | Joint flange |
| 3 | Sealing ring |
| 4 | Oil guide housing to lower part of crankcase Aluminium screw ; always use new aluminium screws > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90° |
| 5 | Oil level sensor |
| 6 | Oil level sensor to oil guide housing (steel screw) > Tightening torque 10 Nm (7.5 ftlb.) ; |
| 7 | Timing-case cover to oil guide housing Aluminium screw; always use new aluminium screws > Initial tightening 4 Nm (3 ftlb.) > and > Final tightening 90° |
Oil pressure sensor and oil pressure measuring point
| 1 | Oil-pressure sensor adapter |
| 2 | Sealing ring |
| 3 | Oil pressure sender with temperature sensor |
| 4 | Screw, M6 x 40 > Tightening torque 10 Nm (7.5 ftlb.) |
| 5 | Stopper > Tightening torque 15 Nm (11 ftlb.) |
| 6 | Sealing ring |
| A | Direction of travel |
Oil lines on naturally aspirated engine
| 1 | Oil pump intake pipe; screw M6 x 20 |
| 2 | Sealing ring |
| 3 | Oil pressure pipe; screw M6 x 16 |
| 4 | Sealing ring |
| 5 | Sealing ring; oil before fitting |
| 6 | Oil regulating line; screw M6 x 16 |
| 7 | Sealing ring |
| 8 | Sealing ring; oil before fitting |
| 9 | Oil pipes to oil pump and oil guide housing > Tightening torque 12 Nm (9 ftlb.) |
| 10 | Oil pipes to oil pump and oil guide housing > Tightening torque 12 Nm (9 ftlb.) |
Oil lines on turbo engine
| 1 | Suction pipe between oil pump and turbocharger (fitted in oil guide housing) |
| 2 | Suction pipe between oil pump and turbocharger (fitted in oil guide housing) |
| 3 | Intake pipe on oil pump |
| 4 | Sealing ring |
| 5 | Oil pressure pipe |
| 6 | Sealing ring |
| 7 | Sealing ring; oil before fitting |
| 8 | Oil regulating line |
| 9 | Sealing ring |
| 10 | Sealing ring; oil before fitting |
| 11 | Oil pipes to oil pump and oil guide housing > Tightening torque 12 Nm (9 ftlb.) |
| 12 | Oil pipes to oil pump and oil guide housing > Tightening torque 12 Nm (9 ftlb.) |
Oil lines on turbo engine, view with oil pan removed
| 1 | Mounting for oil pressure pipe |
| 2 | Mounting for oil extraction line for turbocharger, cylinders 5 to 8 |
| 3 | Mounting for oil extraction line for turbocharger, cylinders 1 to 4 |
| 4 | Mounting for auxiliary sump intake pipe |
| 5 | Mounting for oil pump intake pipe |
| 6 | Mounting for oil regulating line |
Oil lines on naturally aspirated engine, view with oil pan removed
| 1 | Mounting for oil pressure pipe |
| 2 | Mounting for auxiliary sump intake pipe |
| 3 | Mounting for oil pump intake pipe |
| 4 | Mounting for oil regulating line |
Oil pan
| 1 | Oil pan |
| 2 | Seal; replace following removal |
| 3 | Seal; replace following removal |
| 4 | Oil drain plug, M18; aluminium screw; can be reused > Tightening torque 30 Nm (22 ftlb.) |
| 5 | Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.) |
Oil return (oil plate), 2WD
| 1 | Oil guide (oil plate) |
| 2 | Oil return seal |
| 3 | Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.) |
Oil return (oil plate), 4WD
| 1 | Oil guide (oil plate) |
| 2 | Oil return seal |
| 3 | Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.) |
Oil pump, turbo engine
| 1 | Oil pump with extraction staqe |
| 2 | Screw, M8 x 22; replace; 1st turn > Initial tightening 20 Nm (15 ftlb.) ; final tightening (torque angle) > Torque angle 90° |
| 3 | Oil pump sprocket |
| 4 | Cap Screw, M36 > Tightening torque 40 Nm (30 ftlb.) |
| 5 | Oil pressure control valve |
| 6 | Sealing rings (grease before fitting) |
| 7 | Dowel sleeve |
| 8 | Screw, M6 x 45 > Tightening torque 13 Nm (9.5 ftlb.) |
| 9 | Sprocket cover |
| 10 | Screw, M6 x 16 > Tightening torque 10 Nm (7.5 ftlb.) |
| 11 | Drive chain |
Oil pump on naturally aspirated engine
| 1 | Oil pump |
| 2 | Screw, M8 x 22; replace; 1st turn > Initial tightening 20 Nm (15 ftlb.) ; final tightening (torque angle) > Torque angle 90° |
| 3 | Oil pump sprocket |
| 4 | Cap Screw, M36 > Tightening torque 40 Nm (30 ftlb.) |
| 5 | Oil pressure control valve |
| 6 | Sealing rings (grease before fitting) |
| 7 | Dowel sleeve |
| 8 | Screw, M6 x 45 > Tightening torque 13 Nm (9.5 ftlb.) |
| 9 | Sprocket cover |
| 10 | Screw, M6 x 16 > Tightening torque 10 Nm (7.5 ftlb.) |
| 11 | Drive chain |
Suction tube for auxiliary sump
| 1 | Suction tube for auxiliary sump |
| 2 | Sealing ring |
| 3 | Screw, M6 > Tightening torque 12 Nm (9 ftlb.) |
| inset | View of click position |