Fitting the Cylinder Head

1. Carefully blow around the bolt holes in the cylinder block with compressed air.

2. Clean the cylinder head and cylinder block sealing surfaces from any gasket residue. Check with a steel ruler that the cylinder head and cylinder block are level and do not have any damage to the sealing surfaces.

3. Check that the engine is reset to zero via the marking on the pulley and timing cover.

4. Fit a new gasket to the cylinder block. Guide the sprocket up and pull the chain guides together to move the cylinder head down.





Figure 38

5. Remove the camshafts' bearing cap no.2. Fit 83 96 046 kit adjustment tool, camshaft, or 83 96 079 adjustment tool, camshaft (B207 210 hp) on the camshafts.

Tightening torque 10 Nm (7 lbf ft).





Figure 39

6. Fit the cylinder head and fit the bolts in accordance with the sequence indicated in the illustration. Fit the bolts carefully, the threads in the cylinder block are damaged if they are lowered quickly.

Tightening torque step 1: 30 Nm (22 lbf ft)

Tightening torque step 2: 75°

Tightening torque step 3: 80°

Tightening torque, bolts for shaft drive, 25 Nm (18 lbf ft)





Figure 40

7. Remove the bolt to the chain guide. Move the guide back and fit the bolt.

Tightening torque 10 Nm (7 lbf ft).





Figure 41

8. Fit the plug on the cylinder head.

Tightening torque 25 Nm (18 lbf ft)

9. Fit the pinion on the exhaust camshaft and intake camshaft without tightening. Check that the engine is reset to zero.

10. Fit the chain tensioner "zeroed". The groove on the end of the chain tensioner must be down when fitting. See Timing chain tensioner - fitting in accordance with WIS 9-3 (9440) - Engine 4-cyl (petrol) - Basic engine - Adjustment/Replacement. Use 83 96 129 Oil filter tool B207, and chain tensioner, camshaft drive.

Note
Check that the chain tensioner 0-ring and gasket are intact. In the event of damage the complete chain tensioner must be replaced.

Tightening torque 75 Nm (55 lbf ft)

11. Tighten the camshaft pinions. Hold with a wrench on each respective camshaft flat. Remove the cable tie.

Tightening torque 85 Nm +30° (63 lbf ft +30°)

12. Remove the camshaft adjustment tool and fit the camshafts' bearing cap.

Tightening torque 8 Nm (6 lbf ft)

13. Turn over the engine twice and reset to zero so that the markings on the pulley and the timing cover are aligned. Remove the camshafts' bearing caps no.2 and 7 and refit 83 96 046 kit, adjustment tool, camshaft 175 hp or 83 96 079 adjustment tool, camshaft (B207 210 hp) to check that the camshaft setting is correct. Remove the adjustment tools and fit the camshafts' bearing caps.





Figure 42

14. Fit the bolt to the dipstick pipe. Attach the connector and plug it on the pipe.





Figure 43

15. Cars with secondary air injection pump: Fit the pump upper retaining bolt.

Fit the pipe between with pump and the valve.

16. Fit the power steering pump with a new seal.

Tightening torque 22 Nm (16 lbf ft).





Figure 44

17. Connect the coolant hose to the pipe on the cylinder head. Fit the hose to the brake servo.

18. Fit the right-hand engine pad.

Tightening torque, bolts to body 40 Nm + 60° (30 lbf ft + 60°)

Tightening torque, bolts to bracket 70 Nm + 60° (52 lbf ft + 60°)





Figure 45

19. Remove the jack. Connect the coolant hose to the pipe and the cylinder head.

20. Fit the camshaft cover with a new seal.

Tightening torque 10 Nm (7 lbf ft).





Figure 46

21. Connect the ground cable to the camshaft cover.





Figure 47

22. Connect the crankcase ventilation hose to the camshaft cover.

23. Fit the ignition coils.

Tightening torque 8 Nm (6 lbf ft)

24. Fit the wiring harness to the intake manifold and the oil filter housing.





Figure 48

25. Fit the cable duct and bracket to the camshaft cover.





Figure 49

26. Connect the hose to the turbo bypass valve and the solenoid valve.

27. Plug in the A/C pressure sensor connector, the connectors to the coolant temperature sensor, the engine control module, the solenoid valve for the bypass valve, the throttle body, the intake manifold pressure sensor, the atmospheric pressure sensor, the 1DM module, the oil pressure sensor and the ground cable to the engine control module.

28. Plug in the ignition coil connectors. Make sure that the cable is fitted correctly so that it is not trapped by the cover. Plug in the connectors to the turbo solenoid valve and fit the cable clips.





Figure 50

29. Fit the cover over the ignition coils.





Figure 51

30. Press the fuel lines and the ventilation lines into the clips on the camshaft cover. Connect the quick-release coupling for the breather line.





Figure 52

31. Connect both fuel lines to the fuel rail, hold the lower nut. Use new seals.

Tightening torque 10 Nm (7 lbf ft).

32. Fit the air filter housing and connect the inlet hose. Fit the air filter.





Figure 53

33. Fit the air filter housing cover. Plug in the mass air flow sensor connector and fit the turbo intake manifold. Connect the hoses to the turbo intake manifold.





Figure 54

34. Fit the turbocharger delivery hose to the throttle body and the turbocharger delivery pipe.





Figure 55

35. Raise the car. Connect the starter motor positive cable.





Figure 56

36. Fit the stay between the intake manifold and the cylinder block.

Tightening torque 22 Nm (16 lbf ft).

37. Fit the oil return pipe to the turbo. Use a new gasket and a new 0-ring.

Tightening torque 15 Nm (11 lbf ft)





Figure 57

38. Fit the stay between the exhaust manifold and the cylinder block.

Tightening torque 22 Nm (16 lbf ft).

39. Fit the turbo coolant pipe with new seals.

Tightening torque 40 Nm (30 lbf ft)

40. Lower the car and fit the catalytic converter, using new nuts, so that it butts up level to the turbo. Use 30 20 971 Screw-thread paste for the studs.

Tightening torque 25 Nm (18 lbf ft)





Figure 58

41. Raise the car and tighten the bolts to the catalytic converter mounting.

Tightening torque 25 Nm (18 lbf ft)

42. Fit the lower turbocharger delivery pipe.





Figure 59

43. Connect the hose to the headlamp washer and fit and plug in the connector. Fit the lower spoiler shield.

CV: Fit the chassis reinforcement, front subframe.





Figure 60

44. Lower the car slightly and fit the right-hand wing liner and the right-hand front wheel. See WIS - 9-3 (9440) - Suspension, wheels - Wheels and tires - Adjustment/Replacement - Wheels.





Figure 61

45. Fit the turbo oil delivery pipe, use new seals, and hold it so that the pipe does not turn.

Tightening torque 22 Nm (16 lbf ft).





Figure 62

46. Plug in the connectors for the heated oxygen sensors.





Figure 63

47. Fit the heat shield over the turbo.

48. Connect the battery negative cable and the battery cover.





Figure 64

49. Check the oil level and top up as necessary.

50. Fill with coolant to approx. 20 mm above the marking for the expansion tank.





Figure 65

51. Remove the wing cover and reset the car's electrical functions, see WIS - 9-3 (9440) - Engine - 4 cyl (petrol) - Basic engine - Adjustment/Replacement - Measures after disconnecting the battery.

52. Fit the upper engine cover.