To Assemble the Engine

To Assemble the Engine

Clean all engine parts thoroughly prior to fitting.
1. Fit the piston cooling nozzles. Place all main bearings in their correct positions and coat them with oil.
Tightening torque, piston cooling nozzles 18 Nm (13 ft. lbs.).

Important: The field rotor flange must be treated very carefully. Make sure the main bearing adjustment sleeves are unscrewed, if they are not fastened.





2. Fit the slotted ring, place the crankshaft in position and fit the two thrust washers by the main bearing between the No. 2 and No. 3 cylinders. Fit the washers with the embossed side facing towards the main bearing so that the bearing surface is the right way round.
3. Lubricate and fit all main bearing caps in their correct places, making sure that they are the right way round.
Tightening torque 20 Nm + 70 (15 ft. lbs. + 70).





4. Turn the compression rings so that the gaps are staggered 180° and centered with the ends of the gudgeon pin. Also make sure that the gaps in the top and bottom rings of the three-part scraper ring are not in line with each other.
5. Fit protective collars 75 19 531 onto the crankshaft studs, oil the pistons and rings, then fit the pistons in their respective cylinders. The arrow markings on the piston crown should be turned towards the engine's transmission side. Use piston fitting tool 78 62 287 and carefully tap down the pistons in the bores.
6. Oil and fit all big-end bearing caps in their original positions, making sure that they are the right way round (number to number, groove in shell to groove in shell).
Tightening torque 20 Nm + 70 (15 ft. lbs. + 70).





7. Apply a bead of flange seal, part no. 93 21 795, approximately 1 mm wide to the mating face of the end plate and fit the end plate. Be careful with the seal.
8. Align the crankshaft with the wedge straight up (corresponding to the O mark on the crankshaft pulley).
9. Fit the flywheel, alternatively the drive plate, with threadlock, part no. 74 96 292, on the bolts. Make sure the marking points straight up towards the cylinder head.
10. Fit the clutch plate and pressure plate.
11. Fit flywheel locking attachment 83 94 868 and tighten the bolts to torque.
Tightening torque, flywheel and drive plate 20 Nm + 50° (15 ft. lbs. + 50°)





12. Lubricate the bearing surfaces on the balancer shafts and in the bearing housings and insert the balancer shafts into their respective tunnels, taking the utmost care to avoid damaging the bearing shells inside.

Important: Fit the shaft with the small thrust ring marked INL on the inlet side. Fit the shaft with the large thrust ring marked EXH on the exhaust side.

13. Check the timing chain and fit the sprocket and chain onto the crankshaft end, marking to marking. Fit the safety plate in place.
14. First, fit the fixed chain guide, which is common to the timing chain and balancer shaft chain. Then fit the pivoted chain guides for the timing and balancer shaft chains.
15. Fit the balancer-shaft sprocket and the oil-pump driver onto the crankshaft end.





16. Cock the chain tensioner and insert a paper clip or similar object through the hole in the cylinder to prevent triggering of the tensioner. Before this, check that the plunger is turned to the position where it really is pressed out by the spring.
17. Fit the chain tensioner.
Tightening torque: 10 Nm (7 ft. lbs.).

Important: It is extremely important for the function that the correct tightening torque is applied when fitting.





18. Inspect the balancer shaft chain and fit it and the idler sprocket. Make sure the upper setting marks behind the balancer shaft sprocket and bearing housing are in line with each other. Tighten the chain between the crankshaft and balancer shafts. Fit the idler sprocket last. Hold the bolt in place with your thumb, mesh the teeth of the sprocket with the chain and roll it along the chain into position.
19. Check the marking on the balancer-shaft sprocket and remove the flywheel locking attachment.
20. Setting: Fit the timing cover using two bolts only and do not tighten them. Mount the crankshaft pulley. Rotate the pulley one revolution. Reset the crankshaft relative to the timing cover. Remove the timing cover and crankshaft pulley carefully, making sure that the crankshaft does not move, and check the settings of the balancer shafts.
21. Make sure the mating face on the timing cover is completely clean. Apply a bead of flange sealant, part no. 93 21 795, approx. 1 mm wide to the timing cover. Apply the bead in the center of the sealing surfaces.





22. Fit the timing cover. Make sure the upper edge of the cover is in line with the top of the engine block. Apply a 10-20 mm long bead of Loctite 518, part no. 93 21 795, to the inner part of the timing cover's sealing surface (against cylinder head).
Tightening torque 22 Nm (16 ft. lbs.).
23. Fit the flywheel locking attachment and crankshaft pulley. Remove the flywheel locking attachment.
Tightening torque 175 Nm (130 ft. lbs.).





24. Fit the oil pump delivery pipe using a new O-ring and check that there are no impurities or other foreign matter in the oil sump.
25. Fit the adapter housing and oil filter. Use new O-rings lubricated with engine oil.
26. Check that the oil strainer in the sump is clean. Fit with new O-rings.
27. Make sure the mating surface on the oil sump is completely clean. Apply an even coat of flange sealant, part no. 93 21 795. Turn over the engine and fit the oil sump.
Tightening torque 22 Nm (16 ft. lbs.).





28. Carefully clean all sealing surfaces. Apply a 2 mm thick and 10-20 mm long bead of Loctite 518, part no. 93 21 795, to the inner part of the upper contact surface of the timing cover (against the cylinder head). Turn the engine in the stand, turning the crankshaft 45° to lower the pistons.
Fit a rubber band round the chain guides and mount the cylinder head with a new gasket. Check that it is correctly seated on the locating sleeves and that the chain runs freely.
Tighten the cylinder head bolts in three stages:
Step I: 40 Nm (30 ft. lbs.)
Step II: 60 Nm (44 ft. lbs.)
Step III: Tighten a further 90°
Tighten the bolts in the order shown in the illustration.





29. Fit the two screws between the timing cover and the cylinder head.
Tightening torque 22 Nm (16 ft. lbs.).
30. Remove the rubber band and check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the O mark.
31. Fit the camshaft sprockets and chain. Start with the camshaft on the exhaust side. The marking on the sprockets should be in the center of the chain markings (only when the engine is fully zeroed, i.e. crankshaft aligned with the O mark). Do not tighten the bolts yet.





32. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
33. Fit the chain tensioner, using a 27 mm socket.
Tightening torque 63 Nm (47 ft. lbs.).
34. Fit the chain tensioner plug with push rod and spring.
Tightening torque 22 Nm (16 ft. lbs.).
35. Check that the chain is correctly seated in the guides. Rotate the crankshaft two complete turns and check the settings of the crankshaft pulley and camshafts.
36. Tighten the camshaft sprocket bolts.
Tightening torque 63 Nm (47 ft. lbs.).





37. Check the condition of the spark plugs. Replace them if necessary. Fit the spark plugs.
Tightening torque 28 Nm (21 ft. lbs.).
38. Clean the sealing surface of the camshaft cover with benzine.
39. Apply a thin layer of gasket adhesive, part no. 46 20 084, to the outer and inner gasket seats in the camshaft cover. Insert the gaskets.
40. Apply oil to the opening on the camshaft cover and fit the cover, starting at the opening. Then, tighten the bolt located furthest to the front at the timing chain end. Continue all the way round the outside and inside.
Tightening torque 15 Nm (11 ft. lbs.).
41. Fit the banjo pipe to the charge air pipe.
42. Lubricate the ignition discharge module contact surfaces with Krytox, part no. 30 19 312. Fit the ignition discharge module.
Tightening torque 11 Nm (8 ft. lbs.).





43. Inspect the water pump's O-rings and change them if necessary.
Clean the opening in the block and fit the connecting piece with its large wing horizontal and pointing towards the flywheel end.
Lubricate the O-rings with acid-free petroleum jelly and fit the water pump and pipe.
44. Fit the thermostat and thermostat housing.
45. Fit the water pump's delivery and return pipes. Take note of the length of the bolts.
46. Fit the crankshaft position sensor and protective cap.





47. Clean the surface for the gasket and fit a new exhaust manifold gasket.
48. Fit the turbocharger with exhaust manifold and steady bar.
Tightening torque 25 Nm (19 ft. lbs.).
49. Connect the coolant and oil pipes.

Important: The rubber gaskets must be placed closest to the adapter housing and water pump respectively in the cylinder head.

50. Fit the power steering pump bracket.
51. Fit the A/C compressor bracket.
52. Fit the APC valve.





53. Clean all gasket surfaces between the intake manifold and cylinder head.
54. Position the intake manifold gasket using the outer retaining bolts, and fit the intake manifold.
Tightening torque 22 Nm (16 ft. lbs.).

Important: Cars with intermediate piece have a gasket on both sides of the intermediate. (Not applicable to LEV cars)

55. (B235R) Fit the rear lifting eye. Fit the fuel rail with clips.
56. Reconnect the hoses from the throttle body.





57. Fit the oil filler pipe and bracket. Use a new O-ring.
58. Fit the connector bracket by the intake manifold.
59. Man: Fit the gearbox and flywheel access panel.
60. Aut: Fit the gearbox (no access panel)
61. Connect a lifting sling and lift the engine from the stand to the subframe.
62. Remove the retainer.





63. Fit the rear engine mounting bracket and the gearbox retaining bolts. Remove the plug.
64. Change the stuffing box and fit the left-hand drive shaft. Use 83 95 162 Protective sleeve, drive shafts.
65. Position the engine on the subframe and fit the rear engine mounting, tightening it with a torque wrench.
Tightening torque 50 Nm (37 ft. lbs.).
66. Remove the plug and change the stuffing box in the gearbox. Fit the bearing bracket with intermediate shaft and the inboard drive joint. Use fitting tool 83 95 162. Check the fluid level in the gearbox and top up as necessary.
67. Fit the oil trap and connect its hoses.
68. Fit the generator bracket.
69. Fit the intake manifold steady bar.
70. Fit the duct and cable harness.
71. Fit and connect the generator.
72. Fit the starter motor and belt tensioner.
73. Check that the oil plug is properly tightened. Loosely position the auxiliaries drive belt. The power train is now ready for fitting in the car.
Tightening torque 25 Nm (19 ft. lbs.).