To Assemble the Engine
Engine B235RTo assemble the engine
All engine components must be thoroughly cleaned before fitting.
1. Fit the piston cooling nozzles. Place all main bearings in their correct positions and coat them with oil.
Tightening torque: 18 Nm (13 ft. lbs.).
IMPORTANT: Observe the utmost care when handling the slotted ring.
2. Fit the slotted ring, place the crankshaft in position and fit the two thrust washers at 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 in the rings are moved 180° and located directly opposite the gudgeon pin ends. Also make sure that the upper and lower spring gap on the three-piece oil scraper ring are not lined up opposite each other.
5. Fit protective collars 75 19 531 on 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. Lubricate 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.
10. Fit the flywheel locking attachment 83 94 868 and tighten the bolts to torque.
Tightening torques
Flywheel 80 Nm (59 ft. lbs.)
Driven plate 95 Nm (70 ft. lbs.).
11. 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: The shaft with the smaller thrust ring marked INL should be mounted on the inlet side and the shaft with the larger thrust ring marked EXH should be mounted on the exhaust side.
12. Check the timing chain and fit the sprocket and chain onto the crankshaft end, marking to marking, and bolt the safety plate in place.
13. First fit the fixed chain guide, which is common to the timing chain and balancer-shaft chain, and then the pivoted chain guides for the timing and balancer-shaft chains.
14. Fit the balancer-shaft sprocket and the oil-pump driver onto the crankshaft end.
15. 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.
16. Fit the chain tensioner.
Tightening torque: 10 Nm (7 ft. lbs.).
It is extremely important for the function that the correct torque is applied when fitting.
17. Inspect the balancer-shaft chain and fit it and the idler sprocket so that the upper setting marks behind the balancer-shaft sprocket and bearing housing are in line with each other. Tauten 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.
18. Check the marking on the balancer-shaft sprocket and remove the flywheel locking attachment.
19. 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.
20. Make sure the mating face on the timing cover is completely clean. Apply a bead of flange sealant, part no. 93 21 795, approximately 1 mm wide on the timing cover. Apply the bead in the center of the sealing surfaces.
21. Fit the timing cover.
Tightening torque 22 Nm (16 ft. lbs.).
22. Fit the oil pump, flywheel locking attachment and crankshaft pulley. Remove the flywheel locking attachment.
Tightening torque 175 Nm (130 ft. lbs.).
23. Fit the oil pump pressure pipe and check that there are no impurities or other foreign matter in the oil sump.
24. Fit the adapter housing and oil filter.
25. Make sure the mating surface on the oil sump is completely clean and 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.).
26. Swivel the engine in the stand, rotate 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 sockets and that the chain is not trapped.
Tighten the cylinder head bolts in three stages:
Step l: 40 Nm (30 ft. lbs.)
Step 2: 60 Nm (44 ft. lbs.)
Step 3: Tighten a further 90°.
Tighten the bolts in the order shown in the illustration.
27. Fit the two screws between the timing cover and the cylinder head.
Tightening torque 22 Nm (16 ft. lbs.).
28. 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.
29. 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 zeroized, i.e. crankshaft aligned with the O mark). Do not tighten the bolts yet.
30. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
31. Fit the chain tensioner, using a 27 mm socket.
Tightening torque 63 Nm (47 ft. lbs.).
32. Fit the chain tensioner plug with push rod and spring.
Tightening torque 22 Nm (16 ft. lbs.).
33. 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.
34. Tighten the camshaft sprocket bolts.
Tightening torque 63 Nm (47 ft. lbs.).
35. Check the condition of the spark plugs. Replace them if necessary. Fit the spark plugs.
Tightening torque 28 Nm (21 ft. lbs.).
36. Clean the sealing surface of the camshaft cover with benzine.
37. 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.).
38. 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.).
39. Fit the protective cap and the crankshaft position sensor.
40. Inspect the water pump's O-rings and change them if necessary.
Clean the opening in the block and tighten the connecting piece to torque with its large wing horizontal to the flywheel side.
Lubricate the O-rings with acid-free petroleum jelly and fit the water pump and pipe. Fit the clip for the crankshaft position sensor at the same time.
41. Clean the surface for the gasket and fit a new exhaust manifold gasket.
42. Fit the turbocharger with exhaust manifold and steady bar.
Tightening torque 25 Nm (19 ft. lbs.).
43. Connect the water and oil pipes.
IMPORTANT: The rubber seals should be placed against the adapter housing, water pump and cylinder head.
44. Fit the turbo control.
45. Fit the A/C compressor bracket.
46. Fit the servo pump bracket.
47. Fit the boost pressure control valve and hoses to the wastegate.
48. Fit the thermostat housing.
49. Clean all gasket surfaces between the intake manifold and cylinder head.
50. Align the intake manifold gasket with the aid of the outer retaining bolts and fit the intake manifold
Tightening torque 22 Nm (16 ft. lbs.).
51. Reconnect the hoses from the throttle body.
52. Connect ail the electrical connections between the intake manifold and the rest of the power train, and fit the channel in the lifting eye.
53. Fit the oil filler pipe with bracket.
54. Fit the gearbox and flywheel access panel.
55. Connect a lifting sling and lift the engine from the stand to the subframe.
56. Remove the retainer.
57. Fit the rear engine mounting, bracket and the gearbox retaining bolts. Remove the plug.
58. Change the stuffing box and fit the left hand drive shaft.
59. 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.).
60. Fit the front exhaust pipe with sensor. Fit the gearbox steady bar and tighten it, using a torque wrench.
61. Remove the plug and change the packbox in the gearbox. Fit the bearing bracket with intermediate shaft and inboard drive shaft. Check the oil level in the gearbox and top up if necessary.
62. Fit the oil trap and connect its hoses.
63. Fit the intake manifold steady bar.
64. Fit and connect the generator, starter motor and belt tensioner.
65. Check that the oil plug is properly tightened. The power train is now ready for fitting in the car.
Tightening torque 25 Nm (19 ft. lbs.).