Installing valve tappets - cylinder bank 4 - 6

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Check guide for damage. Refer to: CHECKING GUIDE FOR VALVE TAPPET .
Fit guide. Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque 10 Nm (7.5 ftlb.)
Lightly oil the valve tappet and fit it 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 downward.

Fig 1: Groove Or Tab Of The Camshaft Position Sensor Cover Must Face Downward - Cylinder Bank 4-6
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Special tool 9611; fit holding-down device for camshafts. Fit auxiliary screws M6 x 45 with washers and tighten to 10 Nm (7.5 ftlb.).

Fig 2: Fitting Holding-Down Device For Camshafts
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Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Grease bearing surface, fit bearing saddles in correct position and tighten evenly. Tightening torque 10 Nm (7.5 ftlb.)

Fig 3: Identifying Camshaft Bearing Saddles
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E Bearing saddle for inlet camshaft

A earing saddle for exhaust camshaft
Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm (7.5 ftlb.)
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.

Fig 4: Fitting Sprocket Wheel With Chain On Flange Of Exhaust Camshaft
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Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolts M6 x 15 (10.9). Tighten hexagon-head bolts by hand only.
Fit auxiliary chain tensioner, special tool 9599, on cylinder head 4 - 6.

Fig 5: Fitting Auxiliary Chain Tensioner On Cylinder Head 4 - 6
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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 achieved when the measuring pin is flush with the face surface of the pressure screw.

Turn the screw if necessary.
Check whether the auxiliary chain tensioners of cylinder bank 1 - 3 and the auxiliary chain tensioner are fitted on the crankcase half.
Chain tensioner on the crankcase

Fig 6: Identifying Chain Tensioner On Crankcase
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Chain tensioner on cylinder head 1 - 3

Fig 7: Identifying Chain Tensioner On Cylinder Head 1 - 3
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Remove holding-down device 9611.

Fig 8: Removing Holding-Down Device 9611
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Prepare cylinder head cover for installation: Clean sealing surface of the cylinder head and cylinder head cover very carefully. Apply a silicone bead to the cylinder head cover. Refer to: SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER) .

Fig 9: Identifying 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.

Immediately remove silicone material emerging in the area of the camshaft closure cap.

Fasten blocking device (special tool 9612) on the cylinder head.

Fig 10: Fastening Blocking Device On Cylinder Head

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Special tool fitting sequence:

SPECIAL TOOL FITTING SEQUENCE

A -	Fastening screw with star knob on cylinder head lug. Pull back B and C when tightening.
B -	Centring piece in groove of exhaust camshaft. Pull sword bolt (C) back when tightening.
C -	Sword bolt

Allocate camshafts; to do this, turn the pre-tensioned center piece accordingly until the sword bolt can be fixed in the bearing bore.

Fig 11: Turning Pre-Tensioned Centre Piece
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Fasten sprocket wheel. Tightening torque 14 Nm (10.5 ftlb.)
Remove blocking device.
Fit camshaft closure caps (3 ea.) dry.
Fit closure cap on tensioning element (VarioCam). Tightening torque 10 Nm (7.5 ftlb.)
Fit oil supply pump.
NOTE:
- The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation position and direction of rotation must be correct.
Installation position of oil extraction pump at cylinder head 4 - 6 (belt pulley side).

The arrow for the direction of rotation or the marking "4 - 6" 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 ftlb.)

Fig 12: Identifying Arrow For Direction Of Rotation On Oil Extraction Pump - Cylinder Bank 4-6
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Unscrew auxiliary chain tensioner, put new sealing ring on the original chain tensioner and install. Tightening torque 80 Nm (59 ftlb.)

Allocation of chain tensioners

Fig 13: Identifying Chain Tensioners

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CHAIN TENSIONER IDENTIFICATION

A -	Chain tensioner, cylinder bank 4 - 6 Identification "Without"
B -	Chain tensioner on crankcase Identification "1 ring"
C -	Chain tensioner, cylinder bank 1 - 3 Identification "2 rings"

Installation position of the chain tensioners (engine in installed position)

Chain tensioner on the crankcase

Fig 14: Identifying Chain Tensioner On Crankcase

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Chain tensioner on cylinder bank 1 - 3

Fig 15: Identifying Chain Tensioner On Cylinder Bank 1 - 3

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Chain tensioner on cylinder bank 4 - 6

Fig 16: Identifying Chain Tensioner On Cylinder Bank 4 - 6

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