Install Valve Tappet

1. Check guide for damage. Refer to CHECKING GUIDE FOR VALVE TAPPETS .
2. Fit guide. Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque 10 Nm (7.5 ft.lb)
3. Lightly oil the valve tappet and fit it in the guide.
4. 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 upward If the allocation should be uncertain, for example, chain jumped over, reallocation is necessary. Refer to COMPLETING CAMSHAFTS .
   Fig 1: Locating Groove Or Tab Of Camshaft Position Sensor Cover

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5. Special tool 9611; fit holding-down device for camshafts. Fit auxiliary screws M6 x 45 with washers and tighten to 10 Nm (7.5 ft.lb).
   Fig 2: Installing Special Tool (9611) Holding-Down Device For Camshafts

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6. Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Oil bearing surface. Fit bearing saddles in the correct position and tighten evenly. Tightening torque 10 Nm (7.5 ft.lb.)
   Fig 3: Locating Camshaft Bearing Saddle Identification Numbers

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   E = Bearing saddle for inlet camshaft A = Bearing saddle for exhaust camshaft

7. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm (7.5 ft.lb)
8. Unscrew tensioning screw (special tool 9632) from the tensioning element.
9. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.
   Fig 4: Identifying Camshaft Sprocket Wheel & Chain

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10. 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.
11. Unscrew chain tensioner (fitted on the crankcase half of cylinder bank 4 - 6) and fasten auxiliary chain tensioner (special tool 9599).
12. 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.
    Fig 5: Fitting Auxiliary Chain Tensioner

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13. Fit auxiliary chain tensioner on cylinder head 1 - 3 and adjust pre-tension force (refer to step  12).
    Fig 6: Fitting Auxiliary Chain Tensioner - Cylinder Head 1-3

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14. Fit cylinder head cover. Remove holding-down device 9611. 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 7: Applying Silicone Bead To The 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.

15. For the subsequent adjustment work on the camshaft, the pulley must be fixed at bore 1 OT (TDC) with the fixing pin (special tool 9595).
    Fig 8: Installing Special Tool (9595) In Belt Pulley

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16. Fasten blocking device (special tool 9612) on the cylinder head.
    Fig 9: Installing Blocking Device (Special Tool 9612) On The Cylinder Head

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    Special tool fitting sequence: 

    1. Fastening screw with star knob on cylinder head lug. Pull back B and C when tightening. See Fig 9.
    2. Centering piece in groove of the exhaust camshaft. Pull sword bolt (C) back when tightening. Fig 9.
    3. Sword bolt
17. Allocate camshafts; to do this, turn the pre-tensioned Centre piece accordingly until the sword bolt can be fixed in the bearing bore.
    Fig 10: Locating Sword Bolt

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18. Fasten sprocket wheel. Tightening torque 14 Nm (10 ft.lb).
19. Remove blocking device.
    NOTE:

    • The auxiliary chain tensioners must remain fitted on cylinder bank 4 - 6 for the subsequent assembly work.
20. Fit oil extraction 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 1 - 3 (flywheel side): The arrow for the direction of rotation or the marking "1 - 3" 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 ft.lb).

    Fig 11: Locating Oil Extraction Pump Identification Mark - Cylinder Head 1-3 (Flywheel Side)

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21. Fit camshaft closure cap dry.
22. Fit closure cap on tensioning element (VarioCam). Tightening torque 10 Nm (7.5 ft.lb.)

1. Check guide for damage. Refer to CHECKING GUIDE FOR VALVE TAPPETS .
2. Fit guide. Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque 10 Nm (7.5 ft.lb.)
3. Lightly oil the valve tappet and fit it in the guide.
4. 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: Locating Groove Or Tab Of Camshaft Position Sensor Cover

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5. Special tool 9611; fit holding-down device for camshafts. Fit auxiliary screws M6 x 45 with washers and tighten to 10 Nm (7.5 ft.lb).
   Fig 2: Installing Special Tool (9611) Fit Holding-Down Device For Camshafts

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6. 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 ft.lb)
   Fig 3: Locating Bearing Saddle Identification Marks

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   E = Bearing saddle for inlet camshaft A = Bearing saddle for exhaust camshaft

7. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm (7.5 ft.lb.)
8. Unscrew tensioning screw, special tool 9632, from the tensioning element.
9. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.
   Fig 4: Removing Tie Wrap & Fitting Sprocket Wheel With Chain On The Flange Of The Exhaust Camshaft

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10. 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.
11. Fit auxiliary chain tensioner, special tool 9599, on cylinder head 4-6.
    Fig 5: Fitting Auxiliary Chain Tensioner - 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.

12. Check whether the auxiliary chain tensioners of cylinder bank 1-3 and the auxiliary chain tensioner are fitted on the crankcase half.
    Fig 6: Identifying Auxiliary Chain Tensioners

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    Chain tensioner on the crankcase

    Fig 7: Identifying Chain Tensioner On Crankcase - Cylinder Bank 1-3

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    Chain tensioner on cylinder head 1 - 3

13. Remove holding-down device 9611.
    Fig 8: Removing Holding-Down Device (9611)

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14. 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 Sealing Surfaces Of Cylinder Head

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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.

15. Fasten blocking device (special tool 9612) on the cylinder head.
    Fig 10: Installing Blocking Device, Special Tool (9612)

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    1. BFastening screw with star knob on cylinder head lug. Pull back B and C when tightening. See Fig 10.
    2. Centering piece in groove of exhaust camshaft. Pull sword bolt (C) back when tightening. See Fig 10.
    3. Sword bolt
16. Allocate camshafts; to do this, turn the pre-tensioned Centre piece accordingly until the sword bolt can be fixed in the bearing bore.
    Fig 11: Pulling Sword Bolt

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17. Fasten sprocket wheel. Tightening torque 14 Nm (10 ft.lb)
18. Remove blocking device.
19. Fit camshaft closure caps (3 ea.) dry.
20. Fit closure cap on tensioning element (VarioCam). Tightening torque 10 Nm (7.5 ft.lb.)
21. 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 ft.lb)

    Fig 12: Identifying Installation Position Of Oil Extraction Pump - Cylinder Head 4-6

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22. Unscrew auxiliary chain tensioner, put new sealing ring on the original chain tensioner and install. Tightening torque 80 Nm (59 ft.lb)

1. Chain tensioner, cylinder bank 4 - 6 Identification "Without". Refer to Fig 13.
2. Chain tensioner on crankcase Identification "1 ring"
3. Chain tensioner, cylinder bank 1 - 3 Identification "2 rings"

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

Chain tensioner on the crankcase

Chain tensioner on cylinder bank 1 - 3

Chain tensioner on cylinder bank 4 - 6