Installation

1. Thoroughly clean all the flange surfaces for the gaskets, rotate the crankshaft through 45° and install the cylinder head. Make sure that it is correctly seated in the locating sockets and that the chain is not trapped.
2. Install the 10 torx bolts and using the sequence shown, tighten them in three stages:
Stage I: 40 Nm ( 30 ft. lbs. ).
Stage II: 60 Nm ( 44 ft. lbs. ).
Stage III: tighten a further quarter-turn (90°).
3. Install the two bolts securing the timing cover to the cylinder head and tighten to: 22 Nm (16 ft. lbs.).
4. Check that the camshafts are in line with their timing marks and that the 0° mark on the crankshaft is in line with the timing mark.
5. Install the camshaft sprockets and chain.
- Start with the camshaft on the inlet side.
- Do not tighten the bolts yet.
6. Prepare the chain tensioner for installing by pressing down the catch and pushing in the chain tensioner.






7. Install the chain tensioner, using a 27 mm socket, then tighten to: 63 Nm (47 ft. lbs.).
8. Install the plug for the chain tensioner with push rod and spring, then tighten to: 22 Nm (16 ft. lbs.).
9. 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.
10. Tighten the camshaft sprocket bolts to: 63 Nm (47 ft. lbs.).
11. Clean the flanges of the camshaft cover, using a suitable solvent.
12. Apply soap to the open end of the camshaft cover and install 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, tighten to: 15 Nm (11 ft. lbs.).






13. Install the spark plugs and tighten to: 28 Nm (20.7 ft. lbs.).
14. Install the ignition discharge module or the cover plate, tighten to: 11 Nm (8 ft. lbs.).
- Install the ignition cables and distributor cap.
15. Align the intake manifold gasket with the aid of guide pins tool No. 83 94 736, or equivalent, and install the intake manifold, then tighten to: 22 Nm (16 ft. lbs.).
16. Tighten the intake manifold steady bar bolts, beginning with the one in the cylinder block, and plug in the temperature sensor connector.
17. Install the bolts securing the water pipe to the thermostat housing cover and connect the throttle body preheating hose.
18. Install the lifting eyes and the bracket for the electrical connections.
19. Connect the crankcase breather and vacuum hoses and install the dipstick tube and bracket.
20. Plug in the ignition discharge module connector and connect the water pipe for cooling the turbocharger.
21. Connect the coolant hoses to the cylinder head.






22 Install the nuts for the turbocharger, tighten to: 22 Nm (16 ft. lbs.).
- Tighten the bolts securing the turbocharger steady bar, beginning with the one in the block.
23. Install the crankcase breather pipe and inlet pipe.
24. Install the servo pump and install the pulley back in place.
- Install the belt and check the position of all pulleys.
25. Relieve the belt tensioner of strain, using a ratchet handle extension, and remove the drill.
26. Install the pressure pipe between the charge air cooler and the throttle body (turbo)
27. Install the inlet hose and by-pass hose.
28. Install the air cleaner.
29. Connect the negative battery cable, check that the radiator drain plug is tight, top up with coolant and check the system for leaks.
30. Check the coolant and engine oil levels and top up as necessary.
31. Install the cover or resonator, remove the protective sheets over the fenders and check that the engine bay is clean.
32. Start the engine and check all functions.
- Take the car out on a road test.