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CYLINDER HEAD REMOVAL

Removing Vanos Control Unit
• Unscrew oil pipe at VANOS control unit.
Installation Note : Check seals, replacing them is necessary. Torque to 50 ±5 Nm (37 ±3 lb ft) .

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• Unscrew suspension eye.

Installation Note : Check for ground strap (1).

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• Unscrew pulse sender.

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• Remove wiring duct for pulse sender.

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• Remove Thermostat Housing Cover If applicable, unscrew thermostat housing for other
work on cylinder head later.

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Installation Note : Sealing surfaces must be clean and without oil.

Check rubber profile gasket, replacing it if necessary.
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Installation Note : Check installed direction. Vent or arrow faces up. Replace seal.

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Remove Cylinder Head Cover

• If applicable, pull plugs off of ignition coils.
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• Unscrew nuts.
• Remove ignition coils.
Installation Note : Check for ground strap of ignition coils at cylinder 3 and 6.

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• Unscrew cylinder head cover.

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NOTE : Cylinder head cover is separated from the cylinder head as far as transmission of
oscillation is concerned by employing rubber mounts and gaskets.

• Check arrangement of cover installation. 1 Cover nut

2 Washer
3 Rubber mount
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Installation Note : Check cover gasket, replacing it if necessary. Place outer and inner cover
gaskets on cylinder head in advance.

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Installation Note : Check for correct seating of gasket on back of the cylinder head when
mounting the cylinder head cover.

Installation Note : Install and align cover.

• Screw on cover nuts, but do not tighten them.

• Tighten cover nuts diagonally from inside to outside. Torque bolts to: 6 mm 10 Nm (7 ft
lb) 7 mm 15 Nm (11 ft lb) .

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• Take off plastic cover.

• Lift out lock and remove plastic cover for the intake camshaft.

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• Turn engine in its direction of rotation until the peaks of cams on intake and exhaust
camshafts for cylinder no. 1 point to each other.
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• Hold crankshaft in TDC using Special Tool 11 2 300.

CAUTION : Remove special tool before operating the engine.

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• Hold camshafts using Special Tool 11 3 240.

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• Screw plugs out of control unit.

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• Unscrew bolts of sprocket on the exhaust camshaft.

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• Press down on upper chain tensioner and lock using Special Tool 11 3 290.

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• Unscrew nuts.
• Remove VANOS control unit.
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Installation Note : Check for dowel sleeves (1). Apply 3 Bond 1209** liquid sealing compound
at the corners of the joint between the cylinder head and VANOS control unit. Replace gasket.

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• Unscrew nuts of intake camshaft.

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• Remove thrust washer.

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• Remove sprockets together with chain.

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NOTE : If applicable, for work on the cylinder head later.

• unscrew thrust washer bolts.
• Remove thrust washer.

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• Remove sender gear.

Installation Note : Tightening torque.
Sprocket To Camshaft Flange
7mm [1]
Step #1 5 Nm (3.5 ft lb)

Step #2 22 Nm (16 ft lb) .

6mm [1] 10 Nm (7 ft lb) .

Splined Shaft To Intake Camshaft
14X1.5 [1]
Step #1 40 Nm (30 ft lb)

Step #2 Torque Angle 60° .

[1] Screw size.

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• Unscrew secondary tensioner.

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• Unscrew chain guide.

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• Unscrew chain tensioner.

Caution : Spring pressure.
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Installation Note : Align groove in piston perpendicular to the tensioning rail. Replace gasket.

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Arrangement of Parts:
1 - Sleeve
2 - Spring
3 - Piston
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• Press upper chain tensioner down and arrest by inserting Special Tool 11 3 290.
• Unscrew sprockets.
• Lift both sprockets off complete with chain.

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• Unscrew console for upper chain tensioner.

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• Lift sprocket off together with chain.

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CAUTION : Prevent chain from slipping down with a piece of wire.

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Unscrewing Cylinder Head

• Unscrew timing case cover from cylinder head.

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• Unscrew cylinder head bolts in several steps from outside to inside using Special Tool 11
2 250.
• Lift cylinder head off.
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NOTE : Some of the washers are locked in the standard cylinder heads to prevent them from
being lost.

REINSTALL CYLINDER HEAD

-

NOTE : When installing a new cylinder head, install new washers without locking them. Make
sure that no washers are missing. When installing the cylinder head, conform with the waiting
time for hydraulic valve tappets. See: Service Precautions\Vehicle Damage Warnings

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 • Clean mating surfaces on cylinder head and crankcase, if necessary removing remainders
of gaskets with gasket remover and a hard wood scraper. Make sure that remainders of
gaskets do not fall into oil and coolant bores.
• Install new cylinder head gasket.
• Check dowel sleeves (1) for damage and correct installed position.

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NOTE : Gaskets which are 0.3 mm (0.012 in) thicker are available for machined (ground)
cylinder heads.

Identification: 2.5 for 2.5 liter. + 0.3 for 0.3 mm (0.012 in) thicker gasket for repair machined
cylinder head.
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NOTE : Mount cylinder head and tighten new bolts (lightly oiled) in sequence of 1 ... 14 in three
steps.
Step 1: Tightening torque 30 ±2 Nm (22 lb ft)
Step 2: Torque angle 90 ±3°
Step 3: Torque angle 90 ±3°

CAUTION : Cylinder head bolts may only be used once. Keep oil out of tapped bores in the
engine block (danger of cracking the block, wrong tightening torque values).

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Installation Note : Use torque angle tester together with Special Tools 11 2 250 and 11 2 113.

Camshaft Adjusting Procedures

• Hold crankshaft in TDC position with Special Tool 11 2 300.
CAUTION : Remove special tool before operating the engine.

CAUTION : If it is necessary to correct the camshaft adjustment to such an extent that there is
valve movement in cylinders 1 and 6, first turn the crankshaft about 30°away from TDC position
in the engine's direction of rotation and return to TDC only after turning the camshaft. This
prevents contact between the valves and pistons.
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• Turn camshafts until the cam peaks of intake and exhaust cams for cylinder no. 1 face
each other.
• Unscrew the three rear studs for the valve cover.

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• Camshaft may be turned on the hexagon with a 24 mm wrench.

• Hold camshaft with Special Tool 11 3 240.
CAUTION : Be careful that the bearing plate is not damaged. Machine the fork wrench to size
accordingly if necessary.
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• Install primary timing chain on the sprocket and center with the exhaust camshaft. Arrow
on sprocket faces up. Mount sprocket in such a manner that the tapped bores are on the
left hand side of the slots, as the sprocket will be moved to the left when installing the
chain tensioner.

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• Insert special tool 11 3 390 into chain tensioner sleeve (1). Screw in adjusting screw on
tensioning rail as far as stop, but do not tighten.
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NOTE : Sprocket slots are now centered.

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• Install chain guide.

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• Install secondary tensioner.

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• Install pulse sender on the intake camshaft if previously removed.

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CAUTION : Don't mix up studs.

1 Stud for cylinder head cover installation.
2 Stud for thrust washer and sprocket installation.
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• Mount thrust washer and secure with studs (2)

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CAUTION : Mount the intake camshaft sprocket correctly - flat side faces VANOS control unit
and collar faces camshaft.
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• Install both sprockets together with chain.

• Arrow on exhaust camshaft sprocket points up.
• Slots are then centered.
Sprocket To Camshaft Flange
7mm [1]
Step #1 5 Nm (3.5 ft lb)

Step #2 22 Nm (16 ft lb) .

6mm [1] 10 Nm (7 ft lb) .

Splined Shaft To Intake Camshaft
14X1.5 [1]
Step #1 40 Nm (30 ft lb)

Step #2 Torque Angle 60° .

[1] Screw size.
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• Mount thrust washer on intake camshaft and secure with nuts.

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• Mount thrust washer on exhaust camshaft using bolts.

• Screw in bolts to be free of play, but do not yet tighten them.
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NOTE : Check for dowel sleeves (1). Apply 3 Bond 1209** liquid sealing compound on corners
of joint between cylinder head and VANOS control unit. Replace gasket.

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CAUTION : Before installing the VANOS control unit, turn the sprockets together with
secondary chain as far as right-hand stop until slots are aligned with the studs.
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CAUTION : Before mounting the VANOS control unit, push back splined shaft together with
hydraulic plunger (1) in direction of housing (2) as far as stop.

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NOTE : Mount VANOS control unit. Turn splined shaft (1) until splines mesh.
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• Turn chain together with sprockets counter-clockwise by hand until the splined shaft
meshes in the splines of sprocket (2).
CAUTION: It is absolutely essential to ensure that the "FIRST" suitable tooth meshes.

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• Push VANOS control unit in direction of the cylinder head.

• Guiding the bevel splined shaft into the bevel splined sprocket causes the chain together
with sprockets to be turned counter-clockwise.
• Guide chain together with sprockets counterclockwise by hand.
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• Tighten VANOS control unit.

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• Unlock secondary tensioner.

NOTE : It is absolutely necessary to pull the chain into the root of teeth on the sprockets for
timing diagram adjustments since introduction of rubber-lined sprockets.
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• Preload the tensioning rail with 1.3 Nm torque using Special Tool 11 3 390 by turning the
adjusting screw using Special Tool 00 2 050 or a standard torque wrench.

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• Tighten bolts of exhaust camshaft sprocket in two steps as specified.

Sprocket To Camshaft Flange
7mm [1]
Step #1 5 Nm (3.5 ft lb)
Step #2 22 Nm (16 ft lb) .

6mm [1] 10 Nm (7 ft lb) .

CAUTION: Remove Special Tools 11 2 300 and 11 3 240. Crank engine twice in its direction of
rotation.

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• Hold crankshaft in TDC using Special Tool 11 2 300.

CAUTION : Do not crank engine back again. Remove special tool before operating the engine.
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• Check adjustment of camshafts.

• Apply Special Tool 11 3 240 on camshafts at cylinder no. 6.
NOTE : Special Tool 11 3 240 must bear flat on cylinder head without any gaps.

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CAUTION : Always ensure that the timing chain is preloaded with help of Special Tool 11 3
390 when checking the adjustment of camshafts.

• Remove Special Tool 11 3 240 from the cylinder head.

• Loosen Special Tool 11 3 390.
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• Insert chain tensioner plunger.

NOTE : Install chain tensioner plunger (1) that guides engage in the tensioning rail. Install
spring (2) and bolt (3).

Plug For Chain Tensioner

22 mm x 1.5 [1] 50 Nm (37 ft lb)
Cylinder For Chain Tensioner Piston
26 mm x 1.5 [1] 70 Nm (52 ft lb)
[1] Screw size.

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• Replace seal.
• Install plugs.
• Tightening to 29 ft.lbs (40Nm)
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Checking Function of VANOS

• Crank engine in its direction of rotation until the peaks of intake and exhaust cams in
cylinder no. 1 point to each other.
• Hold crankshaft in TDC using Special Tool 11 2 300.
CAUTION : Do not crank engine back again. Remove special tool before operating the engine.

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• Unscrew oil pipe on VANOS control unit.

NOTE : Check seals, replacing them if necessary.
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• Mount Special Tool 11 3 450 using coupling.

• Connect to air pressure supply (2 to 8 bar) .

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• Measure gap between secondary tensioner and edge on the sender gear.
• Note the value.
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• Connect Special Tool 12 6 410 on 4/2-way valve for VANOS.

• Connect battery.
• Ensure that poles are not mixed up.
• Camshaft will be adjusted in advance direction.

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• Measure gap between secondary tensioner and edge on the sender gear.
• NOTE the value.
• The difference between both measured values must be at least 8.5 mm.
• Reassemble covers, manifolds and auxiliary components in reverse order of disassembly,
paying close attention to installation notes and tightening torques..