Installation

Timing Cover

To fit (Engine removed)






NOTE: Step numbers below refer to numbers used in the illustrations.

1. Thoroughly clean off any remnants of sealing compound still adhering to the surfaces concerned. Wash the areas with suitable solvent.

2. Apply a bead of Loctite 518 about 1 mm thick along the middle of the flanges.

3. Fit the timing cover
Tightening torque: 22 Nm (16 ft lbs)

4. Fit the bolt for the support bearing bracket in the timing cover and refit the alternator and belt tensioner.

5. Inspect the water pump O-rings and change them as necessary. Lubricate the O-rings with suitable petroleum jelly (Vaseline) and fit the water pump

6. Fit the crankshaft pulley. Use flywheel locking segment tool No. 83 94 868
Tightening torque: 175 Nm (129.5 ft lbs)

7. Make sure that there are no impurities or other foreign matter in the sump and clean its flange.

8. Apply an even bead of Loctite 518 on the sump flange and fit the sump in place.
Tighten torque: 22 Nm (16 ft lbs)

9. Fit the protective plate, plug in the oil level sensor connector and press the cable back into its clamps.






10. Rotate the crankshaft through 45° and fit the cylinder head with a new gasket. Make sure that it is correctly seated on the locating sockets and that the chain is not trapped.

11. Fit the 10 torx bolts and tighten them in three stages:
Stage I: 60 Nm (44 ft lbs)
Stage II: 80 Nm (59 ft lbs)
Stage III: A further quarter-turn (90°)

12. Fit the two bolts between the timing cover and the cylinder head.
Tightening torque: 22 Nm (16 ft lbs)

13. Check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the 0° mark.

14. Fit the camshaft sprockets and chain. Start with the camshaft on the inlet side.
Do not tighten the bolts yet.

15. Prepare the chain tensioner for fitting by pressing down the catch and pushing in the chain tensioner.

16. Fit the chain tensioner, using a 27 mm socket.
Tightening torque: 63 Nm (47 ft. lbs)

17. Fit the plug for the chain tensioner with push rod and spring.
Tighten torque: 22 Nm (16 ft. lbs)

18. Check that the chain is correctly seated in the guides.
Rotate the crankshaft two complete turns and check that the timing marks on the flywheel and camshafts are still in alignment.

19. Tighten the camshaft sprocket bolts
Tightening torque: 63 Nm (47 ft lbs)






20. Clean the flanges of the camshaft cover, using a suitable solvent.

21. Apply soap to the open end of the camshaft cover and fit the cover, starting at the open end. then tighten the bolt located furthest to the front at the timing end. Then continue all the way round, on both the inside and outside.
Tightening torque: 15 Nm (11 ft lbs)

22. Fit the spark plugs
Tightening torque: 28 Nm (20.7 ft lbs)

23. Fit the ignition discharge module, or ignition cables and the cover plate.
Tightening torque: 11 Nm (8 ft lbs)

24. Plug in the ignition discharge module connector (turbo) and connect the crankcase breather and vacuum hoses to the camshaft cover.

25. Fit the bolts for the thermostat housing cover and reconnect the throttle body preheating hose.

26. Fit the nuts for the turbocharger.
Tightening torque: 25 Nm (18.5 ft lbs)

27. Tighten the bolts for the turbocharger steady bar, starting with the one in the block, and fit the water pipe to the thermostat housing (turbo).

28. Fit the crankcase breather pipe with inlet pipe (turbo).

29. Tighten the bolts for the intake manifold steady bar, starting with the one in the block, and refit the oil filler pipe.

30. Check that the oil drain plug is tight and reconnect the leads to the oil level sensor, oil pressure sensor, alternator and starter motor.