Installation

Fitting
1. Fit the inner gasket for the camshaft cover partition with gasket adhesive, part no. 46 20 084.
2. Position the gasket between the intake manifold and intermediate partition by means of two straps.





3. Thoroughly clean all gasket surfaces. Apply a 2 mm thick and 10 - 20 mm long bead of Loctite 518, part no. 93 21 795 on the inner section of the transmission cover mating face (towards the cylinder head). Fit the cylinder head gasket. Turn the crankshaft 45° in the rotational direction of the engine and fit the cylinder head. Make sure that it enters the locating sleeves correctly and that the chain is in the clear.
4. Fit the Torx-screws on the cylinder head, and tighten them with a torque wrench.
Tightening torque in three stages.
^ Step I: 40 Nm (30 ft. lbs.)
^ Step II: 60 Nm (44 ft. lbs.)
^ Step III: Tighten a further 90°
Tightening sequence for the cylinder head bolts as shown.





5. Fit the two bolts between the timing cover and cylinder head.
Tightening torque 22 Nm (16 ft. lbs.).
6. Check that the camshafts are in line with their timing marks. Reset the crankshaft in line with the 0 mark.
7. Fit the camshaft sprockets and chain. Start with the camshaft on the exhaust side. Do not tighten the bolts yet!





8. Prepare the chain tensioner for fitting by pressing down the catch and pushing in the chain tensioner
9. Fit the chain tensioner, using a 27 mm socket.
Tightening torque 63 Nm (47 ft. lbs.).
10. Fit the chain tensioner plug with push rod and spring.
Tightening torque 22 Nm (16 ft. lbs.).
11. Tighten the bolt on the idler pulley. Tighten the camshaft sprocket bolts. Hold the end of the camshaft with a spanner.
Tightening torque 63 Nm (47 ft. lbs.).
12. 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.
13. Clean the sealing surface of the camshaft cover with benzene.





14. Coat the opening in the camshaft cover thinly with oil. Fit the cover, starting at the opening. Make sure that the cables at the edge of the cover against the intake manifold do not get trapped. Then, tighten the bolt located furthest to the front at the timing chain end. After that, continue all the way round on both the inside and outside.
Tightening torque 15 Nm (11 ft. lbs.).
15. Fit the spark plugs.
Tightening torque 28 Nm (21 ft. lbs.).
Fit the ignition discharge module.
Tightening torque 11 Nm (8 ft. lbs.).
16. Fit the intake manifold with partition but do not tighten. Cut and remove the straps.





17. Tighten the intake manifold, using a torque wrench.
Tightening torque 22 Nm (16 ft. lbs.).





18. Fit the generator bracket. Tap out the adjuster sleeves in the generator bracket about 1 mm to facilitate fitting. Fit the belt tensioner.





19. Tighten the bracket for the ignition discharge module connector in the rear lifting eye and the coolant pipe fitting.
20. Fit the bolt securing the coolant pipe to the thermostat housing cover.
21. Connect the coolant hoses to the cylinder head.
22. Plug in the ignition discharge module and temperature sensor connectors.





23. Fit and tighten the turbocharger retaining nuts between the exhaust manifold and the turbocharger.
Tightening torque 25 Nm (10 ft. lbs.).
24. Fit the heat shield over the turbocharger.
25. Insert the dipstick tube.
26. Raise the car.
27. Tighten the turbocharger steady bar retaining bolts.





28. Tighten the intake manifold steady bar retaining bolts. Fit the dipstick tube correctly in position.
29. Lower the car to the floor.





30. Fit the fuel hoses and refit the rubber protectors.
31. Fit the crankcase ventilation nipple on the valve cover.
32. Tighten the dipstick tube. Attach the throttle cable and adjust as necessary. Fit the ground connections to the cylinder head. Fit the cover over the throttle body spindle.
33. Fit the servo pump. Fit the multigroove belt and check the position of all pulleys.
Tightening torque 20 Nm (15 ft. lbs.)





34. Relieve the belt tensioner with Reliever 83 95 254 and remove the Allen key.





35. Fit the lifting eye, press the rubber into position and plug in the solenoid valve connector.
36. Fit the pressure pipe and bypass valve. Connect the valve's vacuum hose.
37. Fit and connect the mass air flow sensor's rubber gaiter.
38. Fit the engine mounting and tighten with a torque wrench. Make sure the yoke and servo pump pipe bracket are included.
Tightening torque bolts 47 Nm (39 ft. lbs.)
Tightening torque nut 105 Nm (78 ft. lbs.)
39. Remove the wedge. Secure the servo pump pipe to the subframe.
40. Fit the right-hand front wheel.
Tightening torque 110 Nm (80 ft. lbs.)

IMPORTANT: The wheel must hang freely when the wheel bolts are being tightened.

41. Fit the crankcase breather pipe.
Tightening torque banjo connection 24 Nm (18 ft. lbs.)
Tightening torque mounting against camshaft cover 11 Nm (8 ft. lbs.)
42. Connect the negative battery cable. Check that the radiators drain plug is properly tightened. Top up with coolant and check the system for leaks.
43. Check the coolant and oil levels. Top up if necessary.
44. Remove the protective covers from the wings and check that the engine bay is clean.
45. Lower the car to the floor.
46. Bleed the cooling system as follows.
47. Fill with coolant. Do not forget to shut the drain valve on the radiator first Refer to. Coolant for mixtures. Close the cap.
48. Start the engine and run it warm with the heater control on max.
49. Check the coolant level. Top up if necessary.
50. Check all functions. Test drive the car.
Reset the clock and radio code. Calibrate the ACC.