Replacing the right central exhaust valve

• Position special tool 2 249 117 (1) on the camshafts of cylinder bank 1.
• Secure camshafts with the special tool 2 249 117 (1).
• Manually tighten special tool 2 249 117 using two of the cylinder head cover screws (2) until it is against the cylinder head.

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  NOTE: RISK OF DAMAGE
  Damage to timing chain or timing chain drive.
  Turning the engine without chain tensioner or special tool can result in damage to the timing chain and timing chain drive.

  • Always turn the engine with the chain tensioner or the special tool.

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• Release timing chain on the special tool 2 249 162 by turning the hexagon screw (2).
• Leave the special tool 2 249 162 (1) in the cylinder head.
• Loosen screw (1).
• Loosen screw (2).
• Remove slide rails of bank 1 (3).

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• Loosen the VANOS central valve (1).

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• Loosen and remove VANOS central valve (1).
• VANOS adjuster (2) remains on the camshaft.
• For replacement: Replace VANOS central valve.

  Parts: VANOS central valve

• Position VANOS central valve (1).
• Manually push VANOS central valve (1) as far as it will go.

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• Position slide rail of cylinder bank 1 (3).
• Tighten down screw (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Flat-head screw to the slide rail
  Flat-head screw M6x67	Tightening torque	10 Nm

• Tighten down screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Collar screw to the slide rail
  Collar screw M6x48	Tightening torque	10 Nm

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• Screws (1) must be tightened hand-tight.
• Pre-tension timing chain on special tool 2 249 162 at hexagon screw (2) with special tool 0 496 778 (00 9 460) to 0.6 Nm.

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• Place lines near the hexagon head on the VANOS central valves (1) and the VANOS adjusters (2).

  The angle must be 60°.

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• Turn VANOS central valves (1) counterclockwise near the hexagon head to loosen until the top mark on the VANOS central valve lines up with the bottom mark.

  The rotational angle is 60°.

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• Turn the engine counter-clockwise by 90° at the central bolt.

  Make sure the special tools (1) 0 493 882 (11 9 190) and 0 496 366 (11 8 570) (2) do not collide with other components.

• Remove the special tools 0 496 366 (11 8 570) (2).

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• Position special tool (1) 0 493 882 (11 9 190) in the recess in the engine block.

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• Rotate engine on the central bolt clockwise until the special tool 0 493 882 (11 9 190) (1) is against the special tool 0 496 366 (11 8 570) (2).
• Attach the special tool 0 496 366 (11 8 570) (3) to the vibration absorber with a screw from the belt pulley (2) and hand-tighten.
• Remove special tool (1) 0 496 366 (11 8 570).
  NOTE: RISK OF DAMAGE
  Damage to timing chain or timing chain drive.
  Turning the engine without chain tensioner or special tool can result in damage to the timing chain and timing chain drive.

  • Always turn the engine with the chain tensioner or the special tool.
• Check if the screws (1) are applied hand-tight.
• Check preload of tinning chain on special tool 2 249 162 at hexagon screw (2) with special tool 0 496 778 (00 9 460) to 0.6 Nm.
  TIGHTENING TORQUES SPECIFICATION
  
  

  Preload timing chain
  	tightening torque	0.6 Nm

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• Tighten VANOS central valves (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  VANOS central valve initial torque
  VANOS central valve	Joining torque	5 Nm

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• Rotate engine on the central bolt until the special tool lines up with the engine block bridges.
• The special tool 0 496 366 (11 8 570) (3) must be fastened to the vibration absorber with a screw from the belt pulley (2).
• With the crankshaft in the installation position, use the special tool 0 493 882 (11 9 190) (1) to insert it onto the bridges and fasten.

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• Tighten VANOS central valves (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  VANOS central valve second tightening
  VANOS central valve	Joining torque	30 Nm
  	Tightening torque	50 Nm

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• Position special tool 0 490 504 (00 9 120) (1) on the VANOS central intake valve.

  The magnetic base of the special tool 0 490 504 (00 9 120) must be attached to a magnetic component in the engine compartment.

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• Make sure the flexible element of the special tool 0 490 504 (00 9 120) (1) does not collide with other components.
• Set the dial gauge on the special tool 0 490 504 (00 9 120) to zero.

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• Tighten VANOS central intake valve until the needle on the special tool 0 490 504 (00 9 120) is at 30°.
  TIGHTENING TORQUES SPECIFICATION
  
  

  VANOS central valve third tightening
  VANOS central valve	Angle of rotation	30°

• Position special tool 0 490 504 (00 9 120) (1) on the VANOS central exhaust valve.

  The magnetic base of the special tool 0 490 504 (00 9 120) must be attached to a magnetic component in the engine compartment.

• Make sure the flexible element of the special tool 0 490 504 (00 9 120) (1) does not collide with other components.

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• Set the dial gauge on the special tool 0 490 504 (00 9 120) to zero.
• Tighten VANOS central intake valve until the needle on the special tool 0 490 504 (00 9 120) is at 30°.
  TIGHTENING TORQUES SPECIFICATION
  
  

  VANOS central valve third tightening
  VANOS central valve	Angle of rotation	30°

• Loosen screws (2).
• Remove the special tools 2 249 117 (1).

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• Remove the special tool 0 493 882 (11 9 190) (1).
• Release the screw of the belt pulley (2).
• Remove the special tool 0 496 366 (11 8 570) (3).

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• Check the camshaft positions of cylinder bank 1.

  The cams (1) should be in the position shown.

  The increment wheels (2) should each form a straight line with the exhaust camshaft bearing cap and the intake camshaft bearing cap.

  NOTE: Description is for right component only. The procedure on the left side is identical.
  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Ensure that the polished surface of the camshafts (1) point upward.
• Ensure that the rounded surfaces (1) are pointing down at the cylinder head.
• Check timing again and assess.
• Crank the engine at the central bolt in clockwise direction two times until the installation position (MP) (1) of the vibration absorber is positioned flush with the marks of the engine block.
• Position special tool 0 496 366 (11 8 570) (3) on the vibration absorber.
• Position special tool 0 493 882 (11 9 190) (1) in special tool 0 496 366 (11 8 570).
  NOTE: Do not slide the special tool 0 493 882 (11 9 190) (1) too far in; otherwise, it will collide with other components when the crankshaft is turning.
• Rotate the engine on the central bolt in direction of engine rotation until the special tool lines up with the engine block marks.
• Attach the special tool 0 496 366 (11 8 570) (3) to the vibration absorber with a screw from the belt pulley (2) and hand-tighten.
• With the crankshaft in the installation position, use the special tool 0 493 882 (11 9 190) (1) to insert it onto the marks and fasten.

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Check

• Position special tool 2 249 117 (1) on the camshafts of cylinder bank 1.
• Check if the camshafts can be fastened with the special tool 2 249 117 (1).
• Check if the special tool 2 249 117 can be brought in contact with the cylinder head using the two screws of the cylinder head cover (2).

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Result

» The camshafts can be fastened.

Measure

• Timings are OK.

Loosen screws (2).

Remove the special tools 2 249 117 (1).

Continue the repair in the next step.

Result

» The camshafts cannot be fastened.

Measure

• Adjust the timings of cylinder bank 1.
• Remove the special tool 0 493 882 (11 9 190) (1).
• Release the screw of the belt pulley (2).
• Remove the special tool 0 496 366 (11 8 570) (3).

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• Loosen screws (2).
• Remove the special tool 2 249 117 (1).

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