Removing & installing the right valves

CAUTION: Sharp-edge components.
Injury hazard!

Where applicable, cover up or mask off sharp-edged components.

Preliminary work

Refer to REMOVING THE CYLINDER HEAD

Removing the spark plugs of cylinder bank 1 (cylinder head removed)

CAUTION: Swirling dirt particles caused by compressed air.
Injury hazard!

Collect dirt particles, e.g. when blowing out, use cloth to do so.
Wear safety goggles.

NOTE: TECHNICAL INFORMATION
Clean spark plug slot with compressed air.
The spark plug shaft must be cleaned using compressed air after having removed the ignition coils and before removing the spark plugs. After having removed the spark plugs, once again check the sealing surface for contamination and (if necessary) clean using a moist cloth or clean using compressed air.
Deposits that are not removed according to instructions may enter the combustion chamber and lead to uncontrolled combustion. Remaining deposits on the spark plug sealing surfaces may lead to leaks and the spark plugs may come loose during engine operation.
Spark plug threads must not be greased or oiled. Insufficiently tightened spark plugs may cause leaks and the sparks plugs may come loose during engine operation.

NOTE: TECHNICAL INFORMATION
Exclusively swiveling extensions may be used for the reversible ratchet. Rigid mounting tool and variable plug connections with rigid option may not be used; there is a risk that the insulator breaks.

Unscrew the spark plugs with the special tool 0 495 560 (121 220) and an extension with joint.

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Unscrew spark plugs (1) with special tool 0 495 560 (12 1 220) and extension with joint.

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Removing the engine mounting bracket of cylinder bank 1
Loosen screws (2).
Remove the engine mounting bracket (1).

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Attaching cylinder head of bank 1 to assembly jig, and removing and installing

CAUTION: Heavy component.
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

Removing the right intake plenum (cylinder head removed)

Loosen screws (1).
Loosen screws (2).
Guide out right intake plenum.

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Removing right Valvetronic servomotor (cylinder head removed)
Loosen screws (3).
Turn Valvetronic servomotor eccentric shaft (2) counterclockwise to loosen and remove the Valvetronic servomotor (1).

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Installing the cylinder head of cylinder bank 1 on the assembly jig

CAUTION: Heavy component.
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

Get the set of special tools 0 495 187 (00 2 300) ready.

Number	Description
1	Assembly jig
2	Flange
3	Crank
4	cover panel
5	shelf
6	Rear shaped part
7	Collecting vessel
8	Front shaped part
9	Front wheel
10	Rear wheel with stop
11	Rubber mat

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Get the set of special tools 0 494 362 (11 9 000) ready.

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Number	Description
1	Device
2	Rod
3	Adapter
4	Lug
5	Quick tensioning device
6	Aluminum frame insert
7	Shaped part
8	Plastic shaped part
9	lever
10	hook
11	Valve spring cage
12	Valve spring cage
13	Valve spring cage
14	Valve spring cage
15	Valve spring cage
16	Valve spring cage
17	Valve spring cage

Position flange (1) on the assembly jig (2).
Tighten screws (arrows).

TIGHTENING TORQUES SPECIFICATION

Flange to assembly jig
M14X30	Tightening torque	135 Nm

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Slide the device (1) in arrow direction onto the flange (2) and install.
Make sure that the lock (3) engages audibly.

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Loosen screw (1).
Feed out rod (2) in arrow direction and set aside.

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Keep the screws from the set of special tools 0 496 408 (11 8 080) ready.
The washer of the cylinder head bolt (1) must be used.

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Apply the cylinder head (1) hand-tight on the special tool 0 494 362 (11 9 000) in the attachment point area using the screws from the set of special tools 0 496 408 (118 080).

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Removing the exhaust camshaft of cylinder bank 1
Remove the roller tappet (1) from high pressure pump bracket (2).

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Mark the guide bearing shells of the exhaust camshaft from (A1) to (A4) as shown in the graphic.

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Release the screws of the guide bearing in the order (1) to (10) by half a rotation at a time.
Remove the guide bearing shells of the exhaust camshaft.
Remove the exhaust camshaft.

Fig 1: Guide Bearing, Exhaust Camshaft Screws Loosening Sequence
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Remove the roller cam follower of the exhaust side of cylinder bank 1
Detach and remove the roller cam followers (1) on the exhaust side from hydraulic valve clearance compensating elements (arrows).
Place all roller cam followers in order in special tool 0 495 105 (11 4 480).

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Removing hydraulic valve clearance compensating elements on exhaust side of bank 1

Pull all exhaust hydraulic valve clearance compensating elements of the exhaust side (1) up and off.
Place all hydraulic valve clearance compensating elements in proper order on the special tool 0 495105 (11 4 480).

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Remove torsion springs

Prerequisite

If the Valvetronic servomotor is installed, the eccentric shaft must be released via the Valvetronic servomotor.

CAUTION: Spring preload.
Injury hazard!

The use of the specified special tool (tool) is mandatory.
Carry out the described steps properly.

NOTE: The description is for one component only. The procedure is identical for all further components.

The modified locking rods 2 411 031 must be installed on the special tool 2 249 160.

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Position special tool 2 249160 at a downward angle on the torsion spring panel (2).
The lug (1) should be positively locked with the torsion spring panel (2).

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The guide pins (2) in the special tool 2 249 160 should be positively locked with the recesses in the torsion spring panel (1).

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Press lever (1) on the special tool 2 249 160 in the direction of arrow until the latch mechanisms (2) lock.

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Release bolt on the plate of the torsion spring in the area (1).
Guide out special tool 2 249 160 (2) with toe torsion spring and the panel of the torsion spring.

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Connect separate components of the special tool 2 249 160 (3) to (2) and secure with the locking pin (1).
The locking pin (1) should audibly engage.
Clamp special tool 2 249 160 in a standard vice at area (2).

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Use the lever (1) to push special tool 2 249 160 forward to pretension the torsion spring (3).
Pull lever (2) dawn to release the retaining pins (5) from the anti-twist lodes (4).
Carefully release tension on the lever (1) an the special tool 2 249 160.
Remove the torsion spring with the lock plate (3) and place it in the special tool 0 495 105 (114 480) in an ordered position.
Repeat steps for all torsion springs.

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Twist camshaft if necessary.

Removing the sliding block of cylinder bank 1

Position the special tool 2 249166 on the intake camshaft (1) in the area of the sliding block (2) to be disassembled.

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Preload the sliding block (3) with the special tool 2 249166 (2) in direction of arrow.
Loosen screw (1).
Remove the gate (3) and place it arranged in order into 0 495 105 (11 4 480).
Repeat the step for all the gates.

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Removing the intake camshaft of cylinder bank 1
Mark guide bearing shells of the intake camshaft as shown in the graphic from (E1) to (E5).
Slacken the screws of the guide bearings with position numbers (1) and (4) in multiple steps by one half turn at a time.
Remove guide bearing shells.
Remove intake camshaft.

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Remove the intermediate lever of the intake side

Feed out the intermediate lever (1) upward from the roller cam follower (2) and the cam (3) of the eccentric shaft.
Repeat the step for all intermediate levers (1).

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Removing the roller cam follower of the intake camshaft

NOTE: The description is for one component only. The procedure is identical for all further components.

Release and remove the roller cam follower (2) on the intake side from the hydraulic valve clearance compensating element.
Place all roller cam followers in order in special tool 0 495 105 (11 4 480).

Remove all hydraulic valve clearance compensating elements (1) to the top,
Place all hydraulic valve clearance compensating elements into the special tool 0 495105 (11 4 480) along with the roller cam followers in order.

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Removing the eccentric shaft of cylinder bank 1

NOTE: RISK OF DAMAGE
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

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Release all the screws in the marked areas (1).
Twist the eccentric shaft (2) counterclockwise.
Label the bearing brackets as shown in the graphic.
Orderly set down bearing brackets (E1) to (E5) in the special tool 0 495 105 (11 4 480).
Guide out the eccentric shaft (2) toward the top and remove it.

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Setting up cylinder head of bank 1 on special tool 119000

CAUTION: Heavy component.
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

Prepare plastic shaped parts (1) with the shaped parts (2) and aluminum frame insert (3).

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Quick clamping devices (1) on special tool 0 494 362 (11 9 000) (2) must be unlocked.
Insert aluminum frame insert (2).

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Position cylinder head on special tool 0 494 362 (11 9000).
The valves in area (2) must be aligned with the plastic elements (1).

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Cylinder head (1) on special too 0 494 362 (11 9 000) must be hand-tightened In the area of the attachment points with screws from the set of special tools 0 496 408 (11 8 8080).

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Lock quick clamping device (1) on special tool 0 494 362 (11 9 000) (2) In arrow direction.

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Select the correct valve spring page from the set of special tools 0 494 362 (11 9 000).

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Complete special tool 0 494 362 (11 9 000).
Select suitable position on the lever of the valve spring cage (1) and secure hand-tight with the screws.
Hook with damper (2) can be fixed on special tool 0 494 362 (11 9 000) for easier disassembly of the valve shims.

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Remove valves

Position valve spring cage (1) on the valve head.
Push special tool 0 494 362 (11 9 000) down on the lever (3) and attach on the hook (4).
Remove valve shims (2) with magnet.
Detach hook (4).
Relieve lever (3).

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Remove valve spring cup (1).
Remove valve spring (3) and place it arranged in order in the special tool 0 495 105 (11 4 480).
Observe color coding and direction of installation and mark and identify where required.
When replacing the valves, the cylinder head must be detached from the cylinder head 0 494 362 (11 9 000).
Repeat step for all valves.

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Replacing the valve stem seals

NOTE: RISK OF DAMAGE
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.

Disassemble the valve stem seal (1) in arrow direction with the special tool 0 490 796 (11 1 480).

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Remove oil and dirt from the contact surface (1).

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During installation of the valve stem seal, use the special tool 0 490 797 (11 1 960).

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Insert and install special tool 0 490 797 (11 1 960) on the valve (1).

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Insert and install valve stem seal (1) on the special tool 0 490 797 (11 1 960).

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Guide the special tool 0 490 797 (11 1 960) out and remove.

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Press the valve stem seal (1) with the special tool 0 493 249 (116 380) onto the cylinder head until the stop.

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Make sure the valve stem seal (1) is properly positioned on the cylinder head (2).

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Installing valves
When replacing the valves, the cylinder head must be fastened on the special tool 0 494 362 (11 9 000).
Observe the color coding and direction of installation.
Position the valve spring (3).
Position the valve spring cup (1).

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Position valve spring cage (1) on the valve head.
Push special tool 0 494 362 (11 9 000) down on the lever (3) and attach on the hook (4).
Insert the valve shims (2) with a magnet or screwdriver.

Detach hook (4).
Relieve lever (3).
Repeat step for all valves.

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Checking the valves for tightness

WARNING: Working on fuel system.
Risk of fire! Danger of explosion!

When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
No fire, sparks, open flames or smoking.

WARNING: Contact with hazardous fluids.
Hazardous to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

Coat all intake valves with fuel in area (1) on the cylinder head.

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Coat all exhaust valves with fuel in area (1) on the cylinder head.

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Check
Does fuel escape from valves (1) and (2) on the cylinder head?

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Result

» No fuel escapes from the valves or valve seats.

Measure

Continue the repair with the next step.

Result

» Fuel escapes from the valves or valve seats.

Measure

Clean valves, countersink and replace if necessary.

Installing the eccentric shaft of cylinder bank 1

Coat the bearing positions of the eccentric shaft with motor oil.
Insert the eccentric shaft (2) from below and install.
Pay attention to the installation locations of the guide bearing shells (E1) to (E5).
Position bearing brackets as shown in the illustration.

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NOTE: RISK OF DAMAGE
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

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Tighten all screws in the marked areas (1).

TIGHTENING TORQUES SPECIFICATION

Eccentric shaft bearing brackets
Screw M6	Tightening torque	10 Nm

Releasing tension on special tool 119000

CAUTION: Heavy component.
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

Release quick clamp device (1) from the special tool 0 494 362 (11 9 000) (2) in the direction of the arrow.
Remove aluminum frame insert (2).

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Installing the roller cam follower of the intake camshaft

NOTE: The description is for one component only. The procedure is identical for all further components.

If a new hydraulic valve clearance compensating element has not been installed, install in the same position.
Install all hydraulic valve clearance compensating elements (1) downward.
If the roller cam followers are not being replaced, install the roller cam followers in the same position.
Install the roller cam follower (2).

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Checking the intermediate lever classification

NOTE: TECHNICAL INFORMATION
All intermediate levers are classified. Only one classification may be used per engine.
All intermediate levers must be reinstalled in the same positions in an engine which has already been in use.

Checking the intermediate lever classification (arrows).

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Installing intermediate lever on intake side

Position intermediate lever (1) so that it contacts roller cam follower (2) and cam of eccentric shaft (3).
Repeat the step for all intermediate levers (1).

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Install intake camshaft of bank 1
Plastic rings (1) are maintenance free and do not need to be replaced.
Check plastic rings for damage, replace if necessary.

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NOTE: TECHNICAL INFORMATION
The rocker arms may slip slightly when the camshaft is positioned. Make sure rocker arms are correctly positioned on the hydraulic valve clearance compensating elements and on valves.

Position intake camshaft.
When screwing the camshafts, make sure the valves have free movement.
Position guide bearing shells according to marks (E1) to (E5).
Join the screws of the guide bearings with position numbers (1) and (4) in multiple steps by one half turn at a time until flush.
Tighten the screws (1).

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TIGHTENING TORQUES SPECIFICATION

Intake/exhaust camshaft
M6	Tightening torque	10 Nm

Tighten down screws (4).

TIGHTENING TORQUES SPECIFICATION

Intake/exhaust camshaft
M6	Tightening torque	10 Nm

All intermediate levers (3) must rest correctly on the idler pulley (1) and on the camshaft (4).
All intermediate levers (3) must rest correctly on the idler pulley (2) and on the eccentric shaft (5).

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Install sliding blocks of bank 1
Position the special tool 2 249166 on the intake camshaft (1) in the sliding block (2) area.
Remove the oil and dirt from the sliding block (3).
Position the sliding block (3) and abut with the screw (1).
Preload the sliding block (3) with the special tool 2 249166 (2) in direction of arrow.
Tighten down screw (1).

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TIGHTENING TORQUES SPECIFICATION

Sliding block on cylinder head
Screw M7x35 10.9	Tightening torque	20.5 Nm

Relieve the special tool 2 249166 (1) and feed it out of the camshaft (2) and place aside.
Repeat the step for all the gates.

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Installing torsion springs

CAUTION: Spring preload.
Injury hazard!

The use of the specified special tool (tool) is mandatory.
Carry out the described steps properly.

NOTE: The description is for one component only. The procedure is identical for all further components.

Position the torsion springs (3) on the special tool 2 249 160.

The lug in area (1) must be positively locked with the torsion spring panel (3).

The guide pins (2) in the special tool 2 249 160 must be positively locked with the recesses in the torsion spring panel (3).

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Connect individual parts of the special tool 2 249 160 (3) to (2) and secure with the locking pin (1).

The locking pin (1) should audibly engage.

Clamp special tool 2 249 160 in a standard vice at area (2).

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Use the lever (1) to push special tool 2 249 160 forward to pretension the torsion springs (3).
The retaining pins (5) should be secured to the detent (4) on both sides.
Do not operate the release lever (2).

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Feed in the special tool 2 249 160 with the torsion spring.
Position torsion springs in the intermediate levers on the cylinder head.
The ends of the torsion springs (1) must be located in the recesses of the intermediate lever (2).

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Tighten screw at area (1) on the torsion spring panel.

TIGHTENING TORQUES SPECIFICATION

Torsion spring on cylinder head
M6x20 screw	tightening torque	8.8 Nm

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The special tool 2 249 160 (2) must be pre-tensioned.
Press lever (1) on the special tool 2 249 160 in the direction of the arrow until the detents (2) release.

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Press the lever (1) on the special tool 2 249 160 forward to keep the torsion springs (3) tensioned.
Pull lever (2) down to release the retaining pins (5) from the anti-twist locks (4).
Carefully release tension on the lever (1) on the special tool 2 249 160.
Remove the special tool 0 495 105 (11 4 480).
Repeat steps for all torsion springs.

Twist camshaft if necessary.

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Installing hydraulic valve clearance compensating elements on exhaust side of cylinder bank 1

Install all exhaust hydraulic valve clearance compensating elements of the exhaust side (1) downward.

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Installing roller cam follower of the exhaust side of bank 1

Position roller cam followers (1) on exhaust side on the hydraulic valve clearance compensating elements.

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Install exhaust camshaft of the bank 1
Plastic rings (1) are maintenance free and do not need to be replaced.
Check plastic rings for damage, replace if necessary.

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Position exhaust camshaft.
Position exhaust camshaft guide bearing shell.
Screw in guide bearing screws in the order (1) to (10) by a half turn at a time until they can no longer be tightened.
Tighten screws in the order (1) to (10).

Fig 2: Guide Bearing, Exhaust Camshaft Screws Tightening Sequence

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TIGHTENING TORQUES SPECIFICATION

Intake/exhaust camshaft
M6	Tightening torque	10 Nm

Install roller tappet (1) into the high pressure pump bracket (2),

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Remove the cylinder head of cylinder bank 1 from the assembly jig

CAUTION: Heavy component.
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

Release the screws 0 496 408 (118 080) at the special tool 0 494 362 (11 9 000) in the area of the attachment points.
Remove the cylinder head (1).

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Install Valvetronic servomotor, right (cylinder head removed)

NOTE: TECHNICAL INFORMATION
The work must be performed with vehicle care to prevent component damage.

If necessary, lever the radial shaft seal (1) out of the cylinder head using a standard tool.

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Replace radial shaft seal (1) at front.
Parts: Radial shaft seal
Grease the gearing on the worm drive in area (2) using lubricating grease.

Parts: lubricating. grease

CONSUMABLE - LUBRICATING GREASE DESCRIPTION

Lubricating grease	400 g,	83192160340
Longtime PD-1		Cartridge

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Turn the Valvetronic servomotor (1) evenly with the shaft (2) across the gearing of the worm drive as far as it will go.
Secure screws (3).

TIGHTENING TORQUES SPECIFICATION

Valvetronic servomotor on cylinder head
M6x16-8.8	Tightening torque	9.6 Nm

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Installing right intake plenum (cylinder head removed)

Replace the seal (4).

Parts: Gasket

Only during replacement of the intake plenum:

Loosen screws (1).

Unlock pressure sensor (2) on the retaining tab (3).

Remove pressure sensor (2).

Position pressure sensor (2).

Retaining tab (3) must audibly lock in.

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Pressure sensor
screw	Tightening torque	3 Nm

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Position the left intake plenum.
Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Intake plenum
M6 screw	Tightening torque	10 Nm

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Tighten down screws (2).

TIGHTENING TORQUES SPECIFICATION

Intake plenum
M8 screw	Tightening torque	21.4 Nm

Install engine mounting bracket of bank 1

Position engine mounting bracket (1).
Tighten screws (2).

TIGHTENING TORQUES SPECIFICATION

Engine suspension element
M8x22 screw	Tightening torque	20 Nm

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Installing the spark plugs of bank 1 (cylinder head removed)

NOTE: The description is for one component only. The procedure is identical for all further components.

Insert spark plug (1) into special tool 0 496 065 (12 1 230).

NOTE: TECHNICAL INFORMATION
Do not drop spark plug into spark plug shaft! This can lead to a reduction of the electrode gap and can thus impair smooth running of the engine, especially in idle position.

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Make sure the spark plug does not fall into the spark plug shaft.
First screw spark plugs into the engine using special tool 0 496 065 (121 230) and tighten manually.

Tighten spark plugs (1) with a torque wrench, special tool 0 496 065 (121 230) and extension with joint.

TIGHTENING TORQUES SPECIFICATION

Spark plugs
Ml 2x1.25	Tightening torque	23 Nm

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