Assembly

NOTE:
^ Step numbers below refer to numbers used in the illustrations.
^ Wash all sealing surfaces with a suitable cleaning solvent, making sure that they are completely clean.

1. Install the piston cooling nozzles, place all main bearings in their correct positions and coat them with oil.

CAUTION: Observe the utmost care when handling the perforated disc.

2. Install the perforated disc, place the crankshaft in position and Install the two thrust washers at the main bearing between cylinders No. 2 and No. 3.
- Install the washers with their embossed side towards the main bearing so that the bearing surface is the right way round.
3. Lubricate and install the main bearing caps in their correct positions, making sure that they are the right way round, then tighten to: 110 Nm (81.4 ft. lbs.).
4. Rotate the piston compression rings through 180° to bring their gaps in line with the wrist pin bosses.
- Also make sure that the gaps in the three-part scraper ring are staggered and not in line with each other.
5. Install protective collars tool No. 75 19 531, or equivalent, on the connecting rod studs.
- Lubricate the pistons and rings and install the pistons in their cylinders.
- Ensure that the arrow marked on the piston crown faces the timing end of the engine.
- Use piston installing tool No. 78 6 287, or equivalent and gently tap the pistons down into the cylinders.
6. Lubricate and install all big-end bearing caps in their original positions, making sure they are the right way round (number to number, groove in shell to groove in shell), then tighten to 48 Nm (35.5 ft. lbs.).





7. Apply a bead of Loctite 518, or equivalent, about 1.mm thick along the flange of the end plate and install the end plate, being careful of the seal.
8. Install the flywheel or drive plate but do not tighten.
- Apply Loctite 270D, or equivalent, to the bolt threads.
- Install flywheel locking segment tool No. 83 94 868, or equivalent, and tighten as follows:
Flywheel: 80 Nm (59 ft. lbs.).
Drive plate: 95 Nm (70.3 ft. lbs.).
9. Align the 0° mark on the flywheel or driver disc with the mark on the end plate.
10. Lubricate the bearing surfaces on the balance shafts and in the bearing housings and insert the balance shafts into their respective tunnels, taking the utmost care to avoid damaging the bearing shells inside.

Note:
^ The shaft with the smaller thrust ring marked INL is the one for the inlet side of the engine.
^ The shaft with the larger thrust ring marked EXH is the one for the exhaust side of the engine.

11. Check the timing chain and install the sprocket and chain onto the crankshaft end and install the chain guard.
12. First install the fixed chain guide, which is common to the timing chain and balance-shaft chain, and then the pivoted chain guides for the timing and balance-shaft chains.
13. Install the balance-shaft sprocket and the oil-pump driver onto the crankshaft end.





14. Cock the chain tensioner and insert a paper clip or the like through the hole in the cylinder to prevent triggering of the tensioner. Before this, make sure that the plunger is turned to the position where it really is pressed out by the spring.
15. Install the chain tensioner, then tighten to: 10 Nm (7.4 ft. lbs.).

NOTE: It is extremely important for the correct torque to be applied when installing the chain tensioner.

16. Inspect the balance-shaft chain and install it and the idler sprocket so that the setting marks behind the balance-shaft sprocket and on the bearing housing are in line with each other.
- Tighten the chain between the crankshaft and balance shafts.
- Install the idler sprocket last.
- Hold the bolt in place with your thumb, mesh the teeth of the sprocket with the chain and roll the sprocket along the chain into position.
17. Install the top chain guide, pull the chain slightly away from the cylinder block and trigger the tensioner.
- Press the tensioner inwards to check that there is a certain amount of play.
- Rotate the crankshaft one revolution and then check that the chain is set up correctly.
18. Make sure that the flanges on the timing cover are perfectly clean and apply a bead of Loctite 518, or equivalent, about 1.mm thick along the middle of the flanges.
19. Install the timing cover, then tighten to: 22 Nm (16 ft. lbs.).
20. Install the oil pump.





21. Install the oil pump pressure pipe and check that there are no impurities or other foreign matter in the oil pan.
22. Make sure that the flange on the oil pan is scrupulously clean and apply an even layer of Loctite 518, or equivalent, along it.
- Swivel the engine into a suitable position and install the oil pan, then tighten to: 22 Nm (16 ft. lbs.).
23. Swivel the engine round again and rotate the crankshaft through 45°.
- Install the cylinder head, using a new gasket.
- Check that it is correctly seated on the locating pins and that the chain is not trapped.
- Using the sequence shown, tighten the cylinder head bolts in three stages as follows:
Stage I: 60 Nm (44 ft. lbs.).
Stage II: 80 Nm (59 ft. lbs.).
Stage III: A further quarter-turn (90°).
24. Install the two bolts between the timing cover and the cylinder head, then tighten to: 22 Nm (16 ft. lbs.).
25. Check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the 0° mark.
26. Install the camshaft sprockets and chain.
- Start with the camshaft on the inlet side.
- Do not tighten the bolts yet.





27. Prepare the chain tensioner for installing by pressing down the catch and pushing in the chain tensioner.
28. Install the chain tensioner, using a suitable 27 mm socket, then tighten to: 63 Nm (47 ft. lbs.).
29. Install the plug for the chain tensioner with push rod and spring and tighten to: 22 Nm (16 ft. lbs.).
30. 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.
31. Tighten the camshaft sprocket bolts to: 63 Nm (47 ft. lbs.).
32. Glean the flanges of the camshaft cover, using a suitable solvent.
33. 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 to: 15 Nm (11 ft. lbs.).
- Then continue all the way round, on both the inside and outside, tightening to: 15 Nm (11 ft. lbs.).
34. Install the spark plugs, then tighten to: 28 Nm (20.7 ft. lbs.).
35. Install the ignition discharge module or ignition cables and the cover plate and tighten to: 11 Nm (8 ft. lbs.).
36. Install flywheel locking segment tool No. 83 94 868 and tighten the crankshaft pulley to: 175.Nm (129.5 ft. lbs.).
- Remove the locking segment.





37. Install the exhaust manifold and install a new gasket.
- If the exhaust manifold is of two-piece type, install the outer section before the inner section, then tighten to: 25 Nm (18.5 ft. lbs.).
- Check that the contact surfaces for the front pipe are level with each other.
- Note-that spacer sleeves are installed on the outer studs only.
38. Plug in the oil level sensor connector and install the adapter housing with oil filter.
- Install the crankshaft sensor and the thermostat housing cover.
39. Install the power steering pump and bracket.
40. Install the turbocharger and tighten to 22 Nm (16 ft. lbs.).
41. Connect the water and oil pipes.

NOTE: The rubber seals should be placed against the cylinder block.

42. Install the turbocharger steady bar and crankcase breather pipe together with the inlet pipe (turbo).
- Mind the O-ring.
43. Lubricate the O-rings with Vaseline (petroleum jelly) and install the water pump and water pipes from the expansion tank and heat exchanger.
- Install the clips for the crankshaft sensor cable at the same time.
44. Install the bracket for the engine mounting.





45. 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.).
46. Install the intake manifold steady bar and connect the crankcase breather nipple.
47. Connect the cables for the ignition discharge module and temperature sensor, and the hoses for the throttle body.
- Install the oil filler pipe bracket.
48. On models with automatic transmission, check that the torque converter is properly seated in the transmission casing and that the locking screw is installed.
- Install the automatic transmission in place and tighten the bolts.
49. Apply Loctite 270D, or equivalent, to the torque converter bolts threads, then install and tighten to: 60 Nm (44.4 ft. lbs.).
50. On all models, install a lifting sling to the engine and lift it off the stand.
- Remove the fixture and lower the engine onto a trolley.
51. Install the bearing bracket with tube and inner driveshaft joint.
- Install the alternator, reconnect the leads and install the belt tensioner.
52. Install the starter motor and connect the cables.
- Check that the oil plug is properly tightened.
- The engine is now ready for installing into the car.