Installation
Installation of cylinder heads is described separately from removal.
Clean sealing faces of cylinder heads and engine block, if necessary remove gasket debris using a wooden scraper. 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.
Place new cylinder head gaskets in position.
Install cylinder heads. Install new cylinder head bolts. Do not wash off bolt coating.
Note: Use special tool 11 2 250 to tighten down cylinder head bolts.
Use a socket with 3/8" drive and a short extension at narrow points.
Use special tool 00 9 120 as a torsion angle bracket.
Tighten down cylinder head bolts on both cylinder heads in sequence 1 to 10.
Tightening Torque, refer to Engine, Specifications.
Cylinder bank 5 to 8:
Insert the screw and tighten down the slide rail.
Pull up timing chain on both sides and keep tensioned.
Rotate crankshaft from 450 before TDC position in direction of rotation up to TDC firing position. Secure vibration damper with special tool 11 2 300.
Note: Coat all sliding surfaces on VANOS gear with engine oil as lubricant.
Cylinder bank 5 to 8 (inlet side):
Note: The position of the bores in the inlet sprocket wheel (3) can be freely selected; they do not have to line up with the threads yet.
Thread timing chain onto inlet sprocket wheel (3).
Attach inlet sprocket wheel (3) to centering sleeve. Do not insert "any" bolts in inlet sprocket wheel (3) yet.
Cylinder bank 1 to 4 (inlet side):
Keep timing chain tensioned and thread inlet sprocket wheel (3) on.
Attach inlet sprocket wheel (3) to centering sleeve. Do not insert "any" bolts in inlet sprocket wheel (3) yet.
Press tensioning rail against chain and keep tensioned.
Cylinder bank 5 to 8 (inlet side):
Check position of inlet sprocket wheel (3) to threads.
In event of large deviation (thread not visible):
Detach inlet sprocket wheel (3) from centering sleeve, realign sprocket wheel (3) and refit.
In event of small deviation:
Place special tool 11 7 150 on toothed sleeve on exhaust side. Align secondary chain drive to bores in inlet sprocket wheel (3).
Cylinder bank 5 to 8 (inlet side):
Note: The small support diameter of the plate spring (2) points in the direction of the supporting ring (3). Supporting ring is supported with retaining lugs in spline hub (1).
Insert plate spring (2) and supporting ring (3) in spline hub (1).
Cylinder bank 5 to 8 (inlet side):
Install spline hub (1) with plate spring and supporting ring.
Note: Align spline hub (1) so that oil pump drive is positioned as in illustration.
Cylinder bank 5 to 8 (inlet side):
Fit spacer ring (2).
Insert all bolts and initially tighten without play.
Then slacken bolts again until spline hub (1) can be moved with fingers.
Cylinder bank 1 to 4 (inlet side):
Press tensioning rail against chain and keep tensioned. Check position of inlet sprocket wheel (3) to threads.
In event of large deviation (thread not visible):
Detach inlet sprocket wheel (3) from centering sleeve, realign sprocket wheel (3) and refit.
In event of small deviation:
Place special tool 11 7 150 on toothed sleeve on exhaust side. Align secondary chain drive to bores in inlet sprocket wheel (3).
Cylinder bank 1 to 4 (inlet side):
Note: The small support diameter of the plate spring (2) points in the direction of the supporting ring (3). Supporting ring is supported with retaining lugs in spline hub (1).
Insert plate spring (2) and supporting ring (3) in spline hub (1).
Cylinder bank 1 to 4 (inlet side):
Install spline hub (1) with plate spring and supporting ring.
Note: Align spline hub (1) so that oil pump drive is positioned as in illustration.
Cylinder bank 1 to 4 (inlet side):
Fit spacer ring (2).
Insert all bolts and initially tighten without play. Then slacken bolts again until spline hub (1) can be moved with fingers.
Install right timing case cover, refer to Timing Components.
Note: If the chain tensioning piston is re-used, drain the oil chamber in the chain tensioner.
Remove piston for chain tensioner, refer to Timing Components.
Install left timing case cover, refer to Timing Components.
Cylinder bank 1 to 4:
Oil is sprayed when splined shafts are pressed back. Cover bore (1) with a cloth.
Connect special tool 12 6 050 in conjunction with special tool 12 6 411 to solenoid valves of VANOS adjustment unit. Connect special tool 12 6 411 to correct terminals on car battery.
Press buttons 1 and 3 on special tool 12 6 050 simultaneously. Solenoid valves are actuated.
Press splined shafts by hand up to stop into initial position.
Cylinder bank 1 to 4:
Replace O-rings (1 and 2) on VANOS adjustment unit.
Coat O-rings (1) with oil as anti-friction agent.
Caution: O-rings (2) fall out very easily, secure with grease if necessary.
Cylinder bank 1 to 4:
Rotate spline hubs (1) of inlet and exhaust camshafts to right stop.
Cylinder bank 1 to 4:
Attach VANOS adjustment unit.
Cylinder bank 1 to 4:
Caution: Ensure that both VANOS splined shafts remain in initial position during assembly procedure.
Rotate splined shafts of inlet and exhaust sides until straight splines are engaged.
Push VANOS adjustment unit with splined shaft into VANOS gear until helical cut splines (2) are positioned shortly before meshing with spline hub (1).
Cylinder bank 1 to 4 (exhaust side):
If the helical cut splines cannot be pushed into the spline hub (1):
Place special tool 11 7 150 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".
Caution: The "first" fitting tooth must snap into place.
Cylinder bank 1 to 4 (inlet side):
Place special tool 11 7 150 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".
Caution: The "first" fitting tooth must snap into place.
Cylinder bank 1 to 4 (inlet side):
Align radial piston pump to driver on spline hub.
Note: Picture shows a schematic representation.
Cylinder bank 1 to 4:
Push on VANOS adjustment unit only until O-rings of VANOS adjustment unit rest against timing case cover.
Caution: If this position is not reached, realign position of radial piston pump to driver.
Caution: Insert one bolt each on left and right and initially tighten without play. The bolts serve to locate the VANOS adjustment unit in position. Do "not" tighten down bolts yet. VANOS adjustment unit must "not" rest against timing case cover.
Cylinder bank 1 to 4:
Note: Use special tool 11 7 200 to tighten down bolts on VANOS gear.
Tighten down six accessible bolts (three on exhaust side and three on inlet side) on VANOS gear to 10 Nm.
Then slacken all six bolts again by a 1/4 turn.
Cylinder bank 1 to 4:
Install all bolts. Alternately tighten down bolts in 1/2 turn increments carefully and evenly until VANOS adjustment unit rests against timing case cover.
Tighten down all bolts.
Cylinder bank 5 to 8:
Oil is sprayed when splined shafts are pressed back. Cover bore (1) with a cloth.
Connect special tool 12 6 050 in conjunction with special tool 12 6 411 to solenoid valves of VANOS adjustment unit. Connect special tool 12 6 411 to correct terminals on car battery.
Press buttons 2 and 4 on special tool 12 6 050 simultaneously. Solenoid valves are actuated.
Press splined shafts by hand up to stop into initial position.
Cylinder bank 5 to 8:
Replace O-rings (1 and 2) on VANOS adjustment unit.
Coat O-rings (1) with oil as anti-friction agent.
Caution: O-rings (2) fall out very easily, secure with grease if necessary.
Cylinder bank 5 to 8:
Rotate spline hubs (1) of inlet and exhaust camshafts to right stop.
Cylinder bank 5 to 8:
Attach VANOS adjustment unit.
Cylinder bank 5 to 8:
Caution: Ensure that both VANOS splined shafts remain in initial position during assembly procedure.
Rotate splined shafts of inlet and exhaust sides until straight splines are engaged.
Push VANOS adjustment unit with splined shaft into VANOS gear until helical cut splines (2) are positioned shortly before meshing with~ spline hub (1).
Cylinder bank 5 to 8 (exhaust side):
If the helical cut splines cannot be pushed into the spline hub (1):
Place special tool 11 7 150 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".
Caution: The "first" fitting tooth must snap into place.
Cylinder bank 5 to 8 (inlet side):
Place special tool 11 7 150 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".
Caution: The "first" fitting tooth must snap into place.
Cylinder bank 5 to 8 (inlet side):
Align radial piston pump to driver on spline hub.
Note: Picture shows a schematic representation.
Cylinder bank 5 to 8:
Push on VANOS adjustment unit only until O-rings of VANOS adjustment unit rest against timing case cover.
Caution: If this position is not reached, realign position of radial piston pump to driver.
Caution: Insert one bolt each on left and right and initially tighten without play. The bolts serve to locate the VANOS adjustment unit in position. Do "not" tighten down bolts yet. VANOS adjustment unit must "not" rest against timing case cover.
Cylinder bank 5 to 8:
Note: Use special tool 11 7 200 to tighten down bolts on VANOS gear.
Tighten down six accessible bolts (three on exhaust side and three on inlet side) on VANOS gear to 10 Nm.
Then slacken all six bolts again by a 1/4 turn.
Cylinder bank 5 to 8:
Install all bolts. Alternately tighten down bolts in 1/2 turn increments carefully and evenly until VANOS adjustment unit rests against timing case cover.
Tighten down all bolts.
Remove special tool 11 2 300.
Caution: The camshafts remain locked in position with special tool 11 7 120. Carefully rotate engine at central screw against direction of rotation until there is noticeable resistance and spline hubs are at the stop.
Note: This procedure creates compensation for play. Only with this compensation for play is the timing diagram correctly set.
Then crank engine again in direction of rotation until 1st cylinder is at TDC firing position.
Secure vibration damper with special tool 11 2 300.
Cylinder bank 5 to 8:
Note: Use special tool 11 7 200 to tighten down bolts on VANOS gear.
Tighten down six accessible bolts (three on exhaust side and three on inlet side) on VANOS gear to 10 Nm.
Cylinder bank 1 to 4:
Note: Use special tool 11 7 200 to tighten down bolts on VANOS gear.
Tighten down six accessible bolts (three on exhaust side and three on inlet side) on VANOS gear to 10 Nm.
Cylinder bank 1 to 4:
Remove special tool 11 7 120.
Cylinder bank 5 to 8:
Remove special tool 11 7 120.
Remove special tool 11 2 300. Crank engine at central bolt in direction of rotation a further revolution up to overlap TDC position.
Cylinder bank 5 to 8:
Note: Use special tool 11 7 200 to tighten down bolts on VANOS gear.
Tighten down remaining six bolts on VANOS gear to 10 Nm.
Cylinder bank 1 to 4:
Note: Use special tool 11 7 200 to tighten down bolts on VANOS gear.
Tighten down remaining six bolts on VANOS gear to 10 Nm.
Rotate crankshaft in direction of rotation as far as ignition TDC position of cylinder 1. Secure vibration damper with special tool 11 2 300.
Cylinder bank 5 to 8:
Note: The signal rings on the inlet and exhaust camshafts are different.
1. Signal ring for inlet camshaft with one dowel pin
2. Signal ring for exhaust camshaft with two dowel pins
Fit signal rings, align bores (1 and 2).
Cylinder bank 5 to 8:
Install banjo bolt (1).
Grip camshaft at hexagon head and tighten down banjo bolt (1).
Tightening Torque, refer to Engine, Specifications.
Cylinder bank 1 to 4:
Note: The signal rings on the inlet and exhaust camshafts are different.
1. Signal ring for inlet camshaft with one dowel pin
2. Signal ring for exhaust camshaft with two dowel pins
Fit signal rings, align bores (11 and 2).
Cylinder bank 1 to 4:
Install banjo bolt (1).
Grip camshaft at hexagon head and tighten down banjo bolt (1).
Tightening Torque, refer to Engine, Specifications.
Pull special tool 11 2 300 back until vibration damper is no longer secured in position.
Crank engine "twice" in direction of rotation until 1st cylinder is at TDC firing position. Secure vibration damper with special tool 11 2 300.
Cylinder bank 1 to 4:
Check camshaft adjustment.
Note: Groove on 1st bearing cap is a little wider than groove in camshaft.
Groove on inlet and exhaust camshafts must be located inside groove on 1st bearing cap.
Cylinder bank 5 to 8:
Check camshaft adjustment.
Note: Groove on 1st bearing cap is a little wider than groove in camshaft.
Groove on inlet and exhaust camshafts must be located inside groove on 1st bearing cap.
If necessary, adjust camshaft timing, refer to Camshaft, Lifters and Push Rods.
Remove special tool 11 2 300.
Cylinder bank 5 to 8:
Replace sealing rings.
Fit oil line to VANOS adjustment unit.
Tightening Torque, refer to Engine, Specifications.
Cylinder bank 1 to 4:
Replace sealing rings.
Attach oil line to VANOS adjustment unit.
Tightening Torque, refer to Engine, Specifications.
Assemble engine.
Caution: There is air in the VANOS system once it is opened.
In the first few seconds after start-up this results in a clearly discernible "rattling noise".
This rattling noise does "not" indicate incorrect assembly.
The rattling noise will disappear as soon as the oil pressure has built up and the system has vented.