Front Cylinder Head

1. Ensure the crankshaft is at 60° BTDC.
2. Clean all mating surfaces and position the gasket. Note the guides for the gasket and check that it is marked OBEN/TOP.
3. Fit the tappets.





4. Place the cylinder head in position. Use new bolts. Tighten in the order shown.
Tightening torque:
Step I: 25 Nm (18.5 ft. lbs.)
Step II: Tighten a further 90°
Step III: Tighten a further 90°
Step IV: Tighten a further 90°

5. Place the exhaust camshaft in position. Check that it is placed correctly. Lubricate generously with oil.
Cylinders 2-4-6 (front)
The locating pins for the intake camshaft should be in line (downwards) with the inside bolts for the camshaft bearing caps.
The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head.
Observe the markings on the bearing caps and cylinder head. Coat the cylinder head contact surfaces of the front bearing caps sparingly with part No. (10) 74 96 268, see illustration.
Fit the stuffing box and bearing caps and tighten the bolts. Tighten them in steps of 1/2 to 1 turn.
Tightening torque: 8 Nm (6 ft. lbs.)





6. Fit the inner (rear) timing cover.
7. Fit the camshaft sprockets correctly in relation to the locating pins. Check the position against the markings in the timing cover.
The number in the sprocket hub should match the number on the camshaft.
Tightening torque: 50 Nm (37 ft. lbs.) + 60°

WARNING: The jaws of the open-ended spanner used as a counterstay when fitting the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.





8. Check that the O-rings are in place in the camshaft cover and wipe clean. Lubricate with a soap solution and place part No. (1' 81 52 381 in the corners at the camshaft bearing caps.
Tightening torque: 8 Nm (6 ft. lbs.)
9. Fit the ignition discharge module.





10. Fit the turbo oil pipes.
Tightening torque:
Oil pipe, turbo: 20 Nm (15 ft. lbs.)
Oil pipe, oil filter adapter: 20 Nm (18.5 ft. lbs.)
Oil return pipe: 14 Nm (10 ft. lbs.)
11. Fit the turbo's water pipes.
Tightening torque:
Water pipe: 25 Nm (18.5 ft. lbs.)
Cylinder head retaining bolt 14 Nm (10 ft. lbs.)
12. Connect the water hose to the thermostat housing.
13. Fit the front exhaust pipe to the turbo.
Tightening torque: 24 Nm (18 ft. lbs.)





14. Fit the hose between the turbocharger and charge air cooler.
15. Fit the crankcase breather pipe to the turbo intake pipe. Note the gasket.
Tightening torque: 24 Nm (18 ft. lbs.)
16. Fit the turbo intake pipe.
Tightening torque:
V-clamp 3 Nm (2.2 ft. lbs.)
U-clamp cylinder head 14 Nm (10.3 ft. lbs.)
17. Fit the crankcase ventilation pipe between the cylinder head and the turbo intake pipe. Connect the hose from the oil tray.
Tightening torque: Banjo screw, intake pipe 24 Nm (17.7 ft. lbs.)





18. Fit the coolant pump.
Tightening torque: 25 Nm (18.5 ft. lbs.).
19. Fit the bracket with tensioning roller and the upper adjuster roller.





20. Fit locking tool KM-800-1 on No. 1 and No. 2 camshaft sprockets and locking tool KM-800-2 on No. 3 and No. 4 camshaft sprockets
See installation tool for camshaft sprockets and camshaft drive belt
21. Rotate the crankshaft to just before the 0° mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
22. Put on the camshaft belt according to the markings on the belt and the marked direction of rotation. Use KM-800-30 to keep the belt in place. Fit the lower tensioning pulley loosely. Make sure the washer is in place. Adjust the tensioning pulley by hand so that the belt does not jump. Adjust anti-clockwise. "Installation tool for camshaft sprockets and camshaft drive belt". Make sure the markings on the camshaft belt and the corresponding markings on the camshaft sprocket and crankshaft are aligned. Remove the tool KM-800-30.
Fit locking tool KM-800-10, position a piece of camshaft belt and fit tool part no. 83 93 985 "Belt tension meter" to measure the belt tension.
Tighten the center bolts of the adjuster rollers lightly. Adjust the lower adjuster roller anticlockwise until a tension of 275-300 N is obtained. Use tool 83 94 983. Tighten the adjuster roller's bolt. Use tool 83 94 983 as a counterstay. Check the belt tension again and adjust as necessary. Remove the belt-tension meter and piece of camshaft belt.
Tightening torque: 40 Nm (39 ft. lbs.)

IMPORTANT: Adjustment of belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

23. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tighten.
Tightening torque: 20 Nm (15 ft. lbs.)
Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprocket are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay.
Tightening torque: 40 Nm (39 ft. lbs.)
Remove KM-800-20 and the other locking tools.
24. Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.

IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.





25. Fit the coolant bridge. Coat the bolts with (10) 74 96 284. Mind the gaskets.
Tightening torque: 30 Nm (22 ft. lbs.).
26. Fit the lower intake manifold with new gaskets.
Tightening torque: 20 Nm (15 ft. lbs.)
27. Fit the middle intake manifold.
Tightening torque: 20 Nm (15 ft. lbs.)





28. Fit the upper intake manifold with a new gasket.
Tightening torque: 20 Nm (15 ft. lbs.)
29. Connect the fuel lines.
30. Plug in the connectors for the ignition discharge module and injectors.





31. Connect the turbo delivery pipe to the charge air cooler and throttle body.
32. Raise the car, connect the turbocharger delivery pipe to the charge air cooler and throttle body. Tighten the hose clips at the charge air cooler.
33. Lower the car and tighten the hose clip at the throttle body.
34. Plug in the connector for the tamp/pressure sensor. Fit the bypass pipe and valve.





35. Connect the vacuum hose and the two water hoses to the throttle body. Plug in the throttle body connector and attach the hose to the purge valve on the bottom of the throttle body.
Tightening torque: Bypass pipe 8 Nm (6 ft. lbs.)
36. Connect the vacuum hoses and plug in the pressure sensor's connector to the upper intake manifold.
37. Refit the throttle cable.
38. Fit the crankshaft pulley with the notch facing the projection on the engine (diagonally upwards-forwards).
Tightening torque: 20 Nm (15 ft. lbs.)
39. Fit the timing cover.
Tightening torque: 8 Nm (6 ft. lbs.)





40. Fit the belt tensioner and the generator air intake.
41. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 98 292. Do not tighten the bolts.
42. Fit the multigroove belt.
43. Tighten the retaining bolts on the pulleys.
Tightening torque:
Belt pulley/coolant pump: 8 Nm (6 ft. lbs.)
Belt pulley/power steering pump: 20 Nm (15 ft. lbs.)





44. Fit the right-hand engine attachment with bracket and engine mount.
Tightening torque: To body 63 Nm (46.5 ft. lbs.)





45. Fit the power steering hose in the holder
46. Fit the mass air flow sensor with hose.
47. Raise the car.
48. Lower the engine by carefully removing the wedges
49. Fit the turbo bracket. Mind the protective plate for the crankshaft position sensor mounted on the same bracket.
50. Lower the car.
51. Fit the battery with vent hose.
52. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
53. Bleed the cooling system as follows:
Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level.

NOTE: The A/C should be OFF.

54. Raise the car.
55. Check for leakage.
56. Fit the bottom engine cover.
57. Lower the car.
58. Fit the top engine cover and remove the wing protectors.
59. Reset the clock and the radio code, if fitted.