In Car

Valve gear, to remove (in car)





1 Drape the wing protectors over the wings and remove the engine cove
2 Disconnect the negative cable from the battery.
3 Open the cap on the expansion tank and release the pressure.
4 Raise the car.





5 Remove the lower spoiler sections.
6 Drain the coolant from the radiator.





7 Insert two Wedges, part no. 83 95 238, between the oil sump and sub frame and between the gearbox and sub frame.
8 Lower the car.
9 Remove the mass air flow sensor with hose.





10 Detach the power steering hose from the holder. 11 Remove the right-hand engine attachment with bracket and engine mount.

12 Undo the retaining bolts from the coolant pump pulley and power steering pump pulley





13 Release the multigroove belt from tension.
14 Remove the coolant pump pulley and power steering pump pulley.
15 Remove the belt tensioner and generator air intake.
16 Remove the timing cover.
17 Remove the crankshaft pulley.





18 Unhook the throttle cable.
19 Remove the vacuum hoses and unplug the pressure sensors connector from the upper intake manifold.
20 Detach the vacuum hose and the two water hoses from the throttle. Remove the turbo pressure hose with charge air bypass pipe. Unplug the throttle's connector and detach the venting-valve hose from the underside of the throttle.





21 Unplug the connectors for the ignition discharge module and injectors.
22 Detach the fuel lines. 23 Undo the upper intake manifold and move it aside.





24 Remove the middle intake manifold.
25 Remove the lower intake manifold. Plug the holes with paper or the like.





26 Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, U.S. Installation tool for camshaft sprocket KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-1. for the crankshaft.





27 Undo the tensioning pulley and adjusting rollers. Use tool 83 94 983 as a Counterstay on the adjusting rollers.
28 Mark the direction of rotation on the belt. The belt can also be marked with the respective camshaft markings and crankshaft marking to facilitate refitting. Remove tool KM-800-10 from the crankshaft. Let locking tools KM-800-1 and KM-800-2 re mail Remove the lower adjusting roller. Ensure the washer behind the roller is also removed. Remove the timing belt.
29 Remove the bracket with tensioning roller and the upper adjuster roller.





30 Rotate the crankshaft to 60° BTDC. Note the marking.
31 Remove the camshaft sprockets.
32 Remove the coolant pump.
33 Remove the inner timing cover.
34 Remove the ignition discharge module.





35 Remove the camshaft cover. Make sure that the O-rings are in place and that they do not fall into the engine.





36 Undo and remove the camshafts. Undo the bolts in stages, 1/2 to 1 turn at a time. Note the marking on the bearing caps.
It is important to conclude removal at the bearing cap where the tappets are under load. Remove the stuffing boxes.
37 Lift out the tappets using tool 83 91 401.
38 Fit Protective collars part no. 83 95 022 round the valve springs to protect the sealing surfaces of the tappets.
39 Rotate the crankshaft until the piston in the cylinder concerned is at top dead center. Lock the engine using Flywheel locking segment 83 94 868, unscrew the spark plug for the cylinder concerned, use Spark plug socket 83 95 485 and fit Air nipple for spark plug hole 83 94 173. Connect the compressed air and pressurize the piston and valves.





40 Depress the valve heads using valve spring compressor 83 95 246 and remove the tappets.
41 Lift out the spring disc and valve spring and remove valve stem seal using Tong for removing valve stem seals 83 94 157.

Valve gear, to fit (in car)





1 Fit the valve stem seal to the valve. Use carefully tap the seal into position. Use Assembly tool for valve stem seat part no. 83 95 071 and a plastic mallet to carefully tap the seal into position.
2 Fit the spring and spring cap and place the collects in the spring cap groove.
3 Fit the valve cones fit Valve spring compressor part no. 83 95 246.





4 Disconnect the compressed air line, remove the compressed air adapter and the flywheel locking segment.
5 Fit the spark plugs using spark plug socket 83 95 485.
Tightening torque: 25 Nm (118.5 ft. lbs.).
6 Remove the protective sleeves and fit the valve tappets,
7 Rotate the crankshaft to 60° BTDC





8 Place the camshafts in position and fit the stuffing boxes and bearing caps. Start where the cams point downwards and load the tappets. Coat the cylinder head contact surfaces of the front bearing caps sparingly with part No. (10) 74 96 268, see illustration.
Cylinders 1-3-5 (rear)
The locating pin on the camshafts should point towards the inside bolts for the camshaft bearing caps.
Cylinders 2-4-6 (front)
The locating pin 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.
Tightening torque: 8 Nm (6 ft. lbs.)

IMPORTANT: Tighten the bolts in stages - 1/2 to 1 turn at a time. The markings on the camshaft bearing caps and the cylinder head must match.
The caps marked 1-1-1-8 are for the cylinder head with cylinders 1-3-5 and the caps marked R1 -R8 are for the cylinder head with cylinder 2-4-6. The camshaft bearing seats in each cylinder head are numbered 1-8.





9 Check that the O-rings are in place in the camshaft cover and wipe clean. Lubricate with a soap solution and place part No. (11 81 52 381 in the corners at the camshaft bearing caps. Fit the camshaft cover.
Tightening torque: 8 Nm (6 ft. lbs.)
10 Fit the ignition discharge module.





11 Fit the inner (rear) timing cover.
12 Fit the camshaft sprockets correctly in relation to the locating pins.
Tightening torque: 50 Nm (37 ft. lbs.) + 60°





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





15 Fit Installation tool for camshaft so rockets and camshaft drive belt KM-800-1 on no. 1 and no. 2 camshaft sprockets and KN/ 800-2 on no. 3 and no. 4 camshaft sprockets.





16 Rotate the crankshaft to just before the 00 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.
17 Put on the camshaft belt according to the markings on the belt and the marked direction of rotation. Use Setting tool for camshaft sprocket.
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. 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 Belt tension meter part no. 83 93 985 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 Nm is obtained. Use tool 83 94 983. Tighten the adjuster roller's bolt. Use Installation tool for camshaft sprockets and camshaft drive belt 83 94 983 as a Counterstay. Check the belt tension again and adjust as necessary.
Tightening torque: 40 Nm (30 ft. lbs.)
Remove the belt-tension meter and the piece of the camshaft belt

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





18 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 (30 ft. lbs.)
Remove KM-800-20 and the other locking tools
19 Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-1. on tat 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.





20 Fit the lower intake manifold with new gaskets.
Tightening torque: 20 Nm (115 ft. lbs.)
21 Fit the middle intake manifold.
Tightening torque: 20 Nm (115 ft. lbs.)





22 Fit the upper intake manifold with a new gasket.
Tightening torque: 20 Nm (15 ft. lbs.)
23 Connect the fuel lines.
24 Plug in the connectors for the ignition discharge module and injection





25 Connect the vacuum hose and the two water hoses to the throttle. Fit the turbo pressure hose with charge air bypass pipe. Plug in the throttle connector and connect the hose to the venting valve on the underside of the throttle.
Tightening torque:
Bypass pipe 8 Nm (6 ft. lbs.)
26 Connect the vacuum hoses and plug in the pressure sensor's connector to the upper intake manifold.
27 Refit the throttle cable.





28 Fit the crankshaft pulley.
Tightening torque: 20 Nm (15 ft. lbs.)
29 Fit the timing cover.
Tightening torque: 8 Nm (6 ft. lbs.)
30 Fit the belt tensioner and the generator air intake.
31 Fit the coolant pump pulley and the power steering pump pulley. Use Locative, part No. 74 96 292. Do not tighten the bolts.
32 Fit the multigroove belt.
33 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.)





34Fit the right-hand engine attachment with bracket and engine mount,
Tightening torque:
To body 63 Nm (46.5 ft. lbs.)
35 Fit the power steering hose in the holder
36 Fit the mass air flow sensor with hose.
37 Raise the car.





38 Lower the engine by carefully removing the wedges.
39 Lower the car.
40 Reconnect the negative cable to the battery.
41 Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
42 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 vary 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.

43 Raise the car.
44 Check for leakage.





45 Fit the lower spoiler sections.
46 Lower the car.
47 Fit the engine cover and remove the wing protectors
48 Reset the clock and the radio, if fitted.