Engine Installed
(Cylinder bank 1-4)
Prepartion/Finishing
Remove right exhaust manifold.
Unfasten drain plug for coolant on right engine block.
Drain and dispose of coolant.
Installation:
Replace sealing ring.
Tightening Torque, refer to Engine, Specifications.
Vent cooling system and check for leaks, refer to Cooling System.
Remove both cylinder head covers.
Remove spark plugs, refer to Powertrain Management.
Remove fan clutch with impeller, refer to Cooling System.
Remove coolant manifold, refer to Cooling System.
Remove oil lines on left and right of cylinder head.
Removal
Removal of cylinder head is described separately from installation. Assembly sequence for removal and installation is different.
Crank engine at central bolt in direction of rotation until the first cylinder is in TDC position.
Unfasten the accessible three screws on exhaust and inlet camshaft on cylinder bank 5 to 8 approx. 1/2 a turn.
Crank engine once engines up to TDC position of first cylinder.
Note: When unfastening screw connection on camshaft, brace camshaft or hex head.
Caution: Do not damage the cylinder head.
If necessary, machine open-end wrench accordingly.
Unfasten remaining three screws on exhaust and inlet camshafts on cylinder bank 5 to 8 approx. 1/2 a turn.
Remove piston for chain tensioner, refer to Timing Components.
Remove timing case cover, top right, refer to Timing Components.
Remove sprocket on right inlet camshaft (cylinder bank 1 to 4).
Secure chain to prevent it from dropping.
Turn engine on central screw counter-engines up to 45° before TDC position.
Note markings!
Release cylinder-head bolts in sequence 10 to 1
Lift off cylinder head.
Installation
Installation of cylinder head is described separately from removal. Assembly sequence for removal and installation is different.
Clean sealing faces of cylinder head and engine block, if necessary using wooden scraper to remove gasket debris. Ensure that no gasket debris drops into the oil and coolant ducts.
Threaded bores in engine block must be free of dirt and oil (danger of cracking).
Coat joint between engine block and timing case cover with Drei Bond 1209 (or equivalent).
Check that dowel sleeves are undamaged and correctly located.
Fit new cylinder-head seal.
Fit cylinder head and install new cylinder head screws.
Do not wash off screw coating.
Note: Use special tool 00 9 120 as a torsion angle bracket.
Tighten down cylinder head screws in sequence 1 to 10.
Tightening Torque, refer to Engine, Specifications.
Align camshafts with open-end wrench.
Caution: Do not damage the cylinder head.
Fit special tool 11 2 445 / 441 to camshafts on cylinder bank 1 to 4.
Note: In TDC position of first cylinder, marker bores of camshafts point upwards.
Fit special tool 11 2 446 / 442 to camshafts on cylinder bank 5 to 8.
Note: In TDC position of first cylinder, marker bores of camshafts point upwards.
Align all camshafts with open-end wrench in such a way that special tools 11 2 441 / 445 / 446 / 442 locate firmly against cylinder heads.
Caution: Do not damage the cylinder head.
Fit special tool 11 2 443 to special tool 11 2 445 / 441 and secure with special tool 11 2 444 using the spark plug thread.
Fit special tool 11 2 443 to special tool 11 2 446 / 442 and secure with special tool 11 2 444 using the spark plug thread.
Crank engine from the 45° before TDC position in direction of rotational up to TDC position.
Hold crankshaft in TDC position with special tool 11 2 300.
Caution: Remove special tool 11 2 300 before starting engine.
Fit sprocket with chain to inlet camshaft on cylinder bank 1 to 4 with long bores aligned centrally.
Brace sprocket, press bow cover against the timing chain and check the position of the long bores.
If necessary, remove sprocket once again and align position of long bores centrally.
Fit sensor gear with mark on sensor gear in cylinder shaft pointing upwards.
Insert screws and fit flush.
Attach special tool 11 7 380 to right cylinder head (cylinder bank 1 to 4).
Install special tool 11 3 390 in special tool 11 7 380.
Tighten bow cover by turning the adjusting screw on the special tool 11 3 390 with special tool 00 9 250 to 0.7 Nm.
Note: It installation tolerance is unfavorable, attach special tool 00 9 250 from underside.
Tighten sprockets in the following order:
1. Three on exhaust camshaft, left
2. All screws on exhaust camshaft, right
3. Three screws on inlet camshaft, left
4. All screws on inlet camshaft, right
Tightening Torque, refer to Engine, Specifications.
Remove special tools 11 2 444 / 443 / 441 / 445.
Remove special tools 11 2 444 / 443 / 442 / 446.
Remove special tool 11 2 300.
Turn over engine once.
Tighten down remaining three screws in exhaust and intake camshafts on cylinder bank 5-8.
Tightening Torque, refer to Engine, Specifications.
Install oil lines on left and right of cylinder head.
Relieve load on special tool 11 3 390 and remove with special tool 11 7 380.
Install timing case cover, top right.
Install chain tensioning piston.
Assemble engine.