Fitting the Spare Part Cylinder Block
1. Fit 83 94 751 holder and lift the cylinder block into the 78 74 878 floor stand.2. Fit the dipstick pipe with new 0-rings.
Figure 36
3. Fit a new oil filter and replace the 0-ring on the oil filter cover. Use 83 96 121.
Tightening torque 25 Nm (18 lbf ft)
4. Check that the crankshaft has been reset using the markings on the pulley and timing cover.
5. Place a new gasket on the cylinder block.
6. Fit the cylinder head in the order shown in the illustration. Insert the bolts carefully. The threads in the cylinder block can become damaged if they are lowered too rapidly. Check that the guide sleeves function properly.
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 37
7. Fit the balancer shaft chain sprocket and wedge. Fit the balancer shaft chain. Start fitting of the water pump pinion. Continue as follows:
7.A. The silver-coloured link must be fitted to the exhaust side balancer shaft sprocket.
Figure 38
7.B. The copper-coloured link must be fitted to the intake side balancer shaft sprocket.
7.C. The silver-coloured link must be fitted to crankshaft sprocket.
8. Fit the balancer shaft chain guide rails. Use 74 96 268 Thread locking adhesive.
Tightening torque 10 Nm (7 lbf ft)
9. Fit the chain tensioner. Tighten the tensioner by pressing in the plunger and turning it to the right. Secure with tool 83 96 392 Lock pin.
Figure 39
10. Fit the chain tensioner screws. Use 74 96 268 Thread locking adhesive.
Tightening torque 10 Nm (7 lbf ft)
11. Remove the tool from the tensioner. Press the tensioner guide rail to check that backward movement of the plunger is prevented.
12. Fit the crankshaft sprocket.
13. Clean the camshaft and sprocket contact surfaces from oil and grease.
Figure 40
14. Fit the tensioner guide.
Tightening torque 10 Nm (7 lbf ft)
Figure 41
15. Lay the chain on the intake sprocket and lower the chain. Fit the sprocket on the camshaft and tighten the bolt.
16. Fit the chain on the crankshaft sprocket and fit the chain guide. Fit the lower bolt.
Tightening torque 10 Nm (7 lbf ft)
17. Fit the exhaust sprocket and tighten the bolt.
18. Fit the upper bolt. Fit the plug on the cylinder head.
19. Fit the timing chain tensioner using the following method:
19.A. Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position.
Figure 42
19.B. Place the plunger in the chain tensioner sleeve. Fit the circlip and check that it is fitted correctly in the groove.
Note
Check that the 0-ring and gasket are intact. If damaged, replace the chain tensioner assembly.
Figure 43
19.C. Fit the chain tensioner.
Tightening torque 75 Nm (55 lbf ft)
Figure 44
20. Release/activate the chain tensioner by carefully pressing on the timing chain or chain guide (as shown in the illustration). Use a screwdriver. Check that the tensioner releases
Figure 45
21. Remove the exhaust camshaft and intake camshaft bearing caps no.2 and no.7. Position 83 96 046 Adjustment tool, camshaft (B207 150-175 hp) and 83 96 079 Adjustment tool, camshaft (B207 200 hp) by pressing down the tool by hand onto the camshafts without tightening the bolts. Rotate the camshaft with a wrench on the camshaft flats until the tool fits. Tighten the adjustment tool bolts.
Tightening torque 10 Nm (7 lbf ft)
Figure 46
22. Fit the timing cover with a new gasket.
Tightening torque 20 Nm (15 lbf ft)
Figure 47
23. Position the 83 96 202 Fitting tool, front crankshaft seal B207 protective collar on the crankshaft. Lubricate the new sealing ring with acid-free Vaseline and position it on the fitting tool.
Figure 48
24. Position the fitting tool on the crankshaft. Tighten the sealing ring using the crankshaft pulley bolt until it is flush with the timing cover. Remove the tool.
25. Fit the crankshaft pulley with a new bolt. Use 83 95 360 Holding tool, crankshaft pulley (shaft only) and 83 96 210 Holding tool, crankshaft pulley, B207.
Tightening torque 100 Nm + 75° (74 lbf ft + 75°)
26. Check that the markings on the crankshaft pulley and the timing cover are aligned. Tighten the camshaft gears a first time. Use a wrench to grip the camshaft flats.
Tightening torque 30 Nm (22 lbf ft)
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Figure 49
27. Remove the adjustment tool and fit the bearing caps.
Tightening torque 8 Nm (6 lbf ft)
28. Continue to tighten the camshaft gears to the final torque. Use a wrench to grip the camshaft flats.
Tightening torque 85 Nm + 30° (63 lbf ft + 30°)
29. Turn the crankshaft 2 rotations in the engine direction of rotation until the markings on the crankshaft pulley and the timing cover are aligned. Remove the bearing caps and refit 83 96 046 Adjustment tool, camshaft (B207 150-175 hp) and 83 96 079 Adjustment tool, camshaft (B207 200 hp) to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps.
Tightening torque 8 Nm (6 lbf ft)
30. Fit the upper timing chain guide rail.
Tightening torque 10 Nm (7 lbf ft)
31. Fit the belt tensioner.
Tightening torque 50 Nm (37 lbf ft)
Figure 50
32. Fit the engine mounting bracket.
Tightening torque 93 Nm (69 lbf ft)
33. Fit the camshaft cover.
Tightening torque 10 Nm (7 lbf ft)
Figure 51
34. Fit the ground cable.
35. Fit the bracket.
36. Fit the ignition coils.
Tightening torque 8 Nm (6 lbf ft)
37. Fit the 83 94 868 flywheel locking attachment. Fit the flywheel with new bolts. Apply 74 96 292 Thread locking adhesive to the bolts.
Tighten the bolts alternately.
Tightening torque, single mass flywheel 53 Nm + 25° (49 lbf ft + 25°)
Tightening torque, dual mass flywheel 60 Nm +30° (44 lbf ft +30°)
Figure 52
38. Cars with automatic transmission: Fit the driver plate on the crankshaft.
Tightening torque 53 Nm + 25° (49 lbf ft + 25°)
39. Cars with manual gearbox: Place the driven plate and pressure plate on the flywheel and fit the bolts without tightening.
Cars with dual mass flywheel: The convex side of the driven plate must be turned towards the gearbox. Fit the bolts that hold the pressure plate and fit the clutch and driven plate hub.
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Figure 53
40. Centre the driven plate with 87 92 327 Mandrel for centring, driven plate for B207 or 83 96 277 Mandrel for centring, 6-speed and tighten the bolts alternately. Apply 74 96 268 Thread locking adhesive to the threads.
Tightening torque 30 Nm (22 lbf ft)
41. Remove the flywheel locking attachment 83 94 866.
42. Fit the bolt to the dipstick pipe.
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Figure 54
43. Fit the crankshaft position sensor.
44. Fit the lower intake manifold attachment bracket.
Tightening torque 22 Nm (16 lbf ft)
45. Cars with secondary air injection pump: Fit the pump.
Figure 55
46. Fit the generator.
Tightening torque 20 Nm (15 lbf ft)
47. Fit the crankcase ventilation hose to the camshaft cover.
Figure 56
48. Fit the lower turbocharger attachment bracket.
Tightening torque 22 Nm (16 lbf ft)
49. Fit the turbocharger oil return pipe with a new gasket and 0-ring.
Tightening torque 15 Nm (11 lbf ft)
50. Fit the turbocharger oil delivery pipe with new gaskets.
Tightening torque 28 Nm (21 lbf ft)
51. Secure the engine with an engine lift.
52. Raise the engine from the engine stand and carefully lower it onto a pallet, for example. Remove 83 94 751 from the engine.
53. Fit 87 92 442 to the gearbox and raise the gearbox slightly. Fit the gearbox to the engine.
54. Fit the gearbox retaining bolts.
Tightening torque 70 Nm (52 lbf ft)
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Figure 57
Figure 58
55. Raise the engine to the subframe and centre the engine on the subframe with 83 96 152.
56. Fit the torque arms to the oil sump and gearbox.
Tightening torque,
RH torque arm to the oil sump 37 Nm (27 lbf ft)
LH torque arm to the gearbox 70 Nm + 90° (52 lbf ft + 90°)
57. Remove the engine lift.
58. Remove 83 96 178 Lifting eyes, B207.
59. Cars with automatic transmission: Remove 87 92 574 Holder that holds the torque converter in place. Press the torque converter toward the driver plate. Fit the plug.
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Figure 59
60. Cars with automatic transmission: Apply 74 96 268 Thread locking adhesive to the bolts holding the torque converter to the driver plate.
Note
Use the original bolts with accompanying washers. Bolts that are too long can cause damage to the torque converter.
61. Fit the 6 bolts without tightening them.
62. Turn the engine clockwise with the pulley and tighten the bolts when all are in place.
Tightening torque 30 Nm (22 lbf ft)
63. Fit the power steering pump to the cylinder head and replace the gasket.
Tightening torque 22 Nm (16 lbf ft)
Figure 60
64. Fit the coolant-cooled oil cooler with new gaskets.
Tightening torque 22 Nm (16 lbf ft)
65. Fit the starter motor.
Tightening torque 47 Nm (35 lbf ft)
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Figure 61
66. Cars with secondary air injection pump: Fit the pipe between the pump and the valve.
67. Tap the new LH drive shaft seal into place using 87 92 657 Fitting drift, drive shaft seals. Lubricate the seal with gearbox oil.
68. Fit 83 95 162 Protective collar, drive shafts in the sealing ring.
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Figure 62
69. Tap in the RH seal with 87 92 657 Fitting drift, drive shaft seals.
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Figure 63
70. Position 83 95 162 Protective collar, drive shafts in the shaft seal. Insert the intermediate shaft into the gearbox until approximately 20 mm of the shaft remains. Pull out the collar and push in the rest of the intermediate shaft.
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Figure 64
71. Fit the intermediate shaft bracket.
Tightening torque 47 Nm (35 lbf ft)
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Figure 65
72. RH side: Fit the drive shaft in the intermediate shaft splines. Lubricate the shaft splines with 87 81 684 Universal paste. Make sure the seal against the intermediate shaft has been fitted.
73. LH side: Position 83 95 162 Protective collar, drive shafts and fit the drive shaft in the gearbox. Lubricate the shaft splines with gearbox oil. Remove the collar when approximately 20 mm of the shaft remains. Push in the shaft until the circlip snaps into place.
74. Fit the thermostat housing and pipe with new 0-rings. Lubricate the pipe 0-ring sparingly with 30 06 665 Vaseline.
Tightening torque 10 Nm (7 lbf ft)
Figure 66
75. Fit the turbocharger coolant pipe. Fit the banjo screws with new gaskets.
Tightening torque M12, 28 Nm (21 lbf ft)
Tightening torque M14, 40 Nm (30 lbf ft)
76. Fit the breather hose on the cylinder head.
Figure 67
77. Fit the hoses to the oil cooler. Check that the oil cooler hose clamps do not rest against the lower radiator hose. Adjust if necessary.
78. Fit the catalytic converter with new nuts. Lubricate with 30 20 971 Screw-thread paste.
Tightening torque 25 Nm (18 lbf ft)
Figure 68
79. M03: Plug in the temperature sensor connector.
80. Press the oxygen sensor connectors firmly into place.
81. Fit the catalytic converter heat shield.
Tightening torque 10 Nm (7 lbf ft)
Figure 69
82. Fit the turbocharger heat shield.
Tightening torque 10 Nm (7 lbf ft)
83. Fit the lower charge air pipe.
Tightening torque 22 Nm (30 lbf ft)
84. Position the engine wiring harness and plug in the following connectors:
84.A. Plug in the connector to the charge air control valve.
Figure 70
84.B. Plug in the connector to the coolant temperature sensor.
84.C. Plug in the engine control module connector.
84.D. Plug in the engine control module connector.
84.E. Plug in the connector to grounding point G7.
84.F. Plug in the bypass valve connector.
84.G. Plug in the throttle body connector.
84.H. Plug in the 4 ignition coil connectors.
84.I. Plug in the connector to the ionization detection module.
Figure 71
84.J. M03: Plug in the connector to the exhaust temperature sensor.
84.K. Plug in the connector to the front oxygen sensor.
84.L. Plug in the connector to the rear oxygen sensor.
84.M. Plug in the connector to the atmospheric pressure sensor.
X��:
Figure 72
84.N. Plug in the connector to the intake manifold pressure sensor.
84.0. Fit the power steering fluid pressure switch.
84.P. Fit the starter motor contacts.
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Figure 73
84.Q. Cars with secondary air injection pump: Plug in the secondary air injection pump connector.
84.R. Fit the oil pressure switch.
84.S. Plug in the connector to the crankshaft position sensor.
84.T. Plug in the EVAP canister purge valve connector.
84.U. Plug in the oil level sensor connector.
84.V. Plug in the generator connector.
84.W. Plug in connector H8-9.
84.X. Cars with manual gearbox: Plug in the reverse light connector.
84.Y. Fit the wiring harness retaining bolts.
85. Fit the cover to the spark plugs.
Figure 74
86. Fit the engine assembly, see WIS - 9-3 (9440) - Engine - 4-cylinder petrol - Basic engine - Adjustment/Replacement - Fitting the power train.
87. Fill with engine oil, see WIS - 9-3 (9440) - Engine - 4 cylinder petrol - Basic engine - Adjustment/Replacement - Changing engine oil and oil filter.
88. Fill with gearbox oil:
Cars with automatic transmission: See WIS - 9-3 (9440) - Transmission - Automatic transmission - Adjustment/Replacement - Checking transmission fluid level.
Cars with manual gearbox: See WIS - Transmission - Manual gearbox - Adjustment/Replacement - Refilling with gearbox oil.
89. CV: Fit the chassis reinforcement, front subframe.
90. Lower the car.
91. Complete the procedures after disconnecting the battery, see WIS - 9-3 (9440) - Electrical System - Charging system - Adjustment/Replacement - Procedures after disconnecting the battery.