Rear Cylinder Head, to Fit (In Car)

Rear Cylinder Head, To Fit (In Car)





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.

Important: Make sure the correct gasket is selected. (Thinner for LEV engines)

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 1-3-5 (rear)
The locating pins for the camshafts should point to the inside bolts for the camshaft bearing caps.

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.
Tightening torque: 50 Nm (37 ft. lbs.) + 60°

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





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





10. Connect the hose to the SAI pipe and check the connection.
11. Fit the SAI pipe with new gaskets to the exhaust manifold and cylinder head.
12. Fasten the oxygen sensor connector in the holder.





13. Raise the car and fit the front exhaust pipe to the rear exhaust manifold.
Tightening torque: 40 Nm (29.5 ft. lbs.).





14. Lower the car and fit the coolant pump.
Tightening torque: 25 Nm (18.5 ft. lbs.).





15. Fit the bracket with tensioning roller and the upper adjuster roller.
16. 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.





17. 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.





18. Put on the camshaft belt according to the markings on the belt and the marked direction of rotation. Use Installation tool for camshaft sprockets and camshaft drive belt 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 centre 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 tool 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 piece of the toothed 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.





19. 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.

20. 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.





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





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





27. Connect the turbo delivery pipe to the throttle body.
28. 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.
29. Refit the throttle cable.
30. Raise the car and connect the turbocharger delivery pipe to the charge air cooler. Tighten the hose clip on the charge air cooler. Lower the car.





31. Connect the vacuum hoses and plug in the pressure/tamp sensor connector to the upper intake manifold.
32. Fit the turbo bypass pipe and valve. Plug in the connector for the pressure/tamp sensor.
Tightening torque 8 Nm (6 ft. lbs.).
33. Fit the crankshaft pulley with the notch facing the projection on the engine (diagonally upwards-forwards).
Tightening torque: 20 Nm (15 ft. lbs.).





34. Fit the timing cover.
Tightening torque: 8 Nm (6 ft. lbs.).
35. Fit the belt tensioner and the generator air intake.
36. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
37. Fit the multigroove belt.
38. 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.).





39. Fit the right-hand engine attachment with bracket and engine mount.
Tightening torque: To body 63 Nm (46.5 ft. lbs.).
40. Fit the power steering hose in the holder
41. Fit the mass air flow sensor with hose.
42. Raise the car.
43. Lower the engine by carefully removing the wedges.





44. Lower the car.
45. Reconnect the negative cable to the battery.
46. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
47. 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.

48. Raise the car.
49. Check for leakage.
50. Fit the bottom engine covers.





51. Lower the car.
52. Fit the engine cover and remove the wing protectors.
53. Reset the clock and the radio code, if fitted.