Fitting of Cylinder Head

Cylinder head





To fit
1. Carefully blow clean the bolt holes in the cylinder block with compressed air.
2. Clean the cylinder bores and the sealing surfaces on the cylinder head and cylinder block from gasket remains. Check the flatness of the cylinder head and cylinder block with a steel rule and inspect for damaged sealing surfaces.
3. Check with the marks on the pulley and the timing cover that the engine is zeroed.
4. Place a new gasket on the cylinder block. Lift up the sprocket and pull the chain guides together to lower the cylinder head.





5. Remove exhaust camshaft and intake camshaft no. 2 bearing caps. Fit 83 96 046 Camshaft adjustment tool kit to the camshafts.
Tightening torque 10 Nm (7 ft. lbs.).





6. Fit the cylinder head in the order shown in the illustration. Insert the bolts carefully. The threads in the cylinder block will be damaged if they are dropped too rapidly.
Tightening torque, step 1: 30 Nm (22 ft. lbs.)
Tightening torque, step 2: 150°
Tightening torque, step 3: 15°





7. Remove the bolt for the chain guide. Put back the guide and screw in the bolt again.
Tightening torque 10 Nm (7 ft. lbs.).





8. Fit the plug on the cylinder head. Use a new sealing washer.
Tightening torque 25 Nm (18 ft. lbs.).
9. Fit the pinion on the exhaust camshaft and intake camshaft without tightening. Check that the engine is zeroed.
10. Fit the chain tensioner "reset" with a new seal. The groove on the end of the chain tensioner should be vertical when fitted. Use 83 96 129 Oil filter tool, B207, and camshaft drive chain tensioner
Tightening torque 75 Nm (55 ft. lbs.).
11. Tighten the camshaft pinions. Grip the respective camshaft flats with a spanner. Remove the cable tie.
Tightening torque 85 Nm + 30° (63 ft. lbs. + 30°)
12. Remove the camshaft adjustment tool and fit the camshaft caps.
Tightening torque 8 Nm (6 ft. lbs.).
13. Turn over the engine twice and zero it so that the markings on the pulley and the timing cover are aligned. Remove bearing caps 2 and 7 and refit 83 96 046 Camshaft adjustment tool kit 175 hp to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps.





14. Clean the sealing surfaces on the intake manifold and the cylinder head. Fit the intake manifold with a new gasket.
Tightening torque 10 Nm (7 ft. lbs.).





15. Connect the vacuum hose to the fuel pressure regulator.





16. Fit the screw for the dipstick.
17. Connect the vacuum hose and the purge hose to the intake manifold.
18. Plug in the injector connectors.





19. Fit the throttle body and the engine control module. Leave the upper right screw for the ground cable.
Tightening torque 10 Nm (7 ft. lbs.).





20. Fit the bracket and connect the quick-release coupling to the EVAP canister purge valve.
21. Fit the power steering pump with a new seal.
Tightening torque 22 Nm (16 ft. lbs.).





22. Connect the hose quick-release couplings to the vacuum pump, fit the IDM module and connect the coolant hose to the pipe on the cylinder head.
23. Fit the right-hand engine pad.
Tightening torque, bolts in body 40 Nm + 60° (30 ft. lbs. + 60°)
Tightening torque, bolts in bracket 70 Nm + 60° (52 ft. lbs. + 60°)





24. Connect the coolant hose to the pipe and cylinder head.
25. Fit the camshaft cover with a new seal.
Tightening torque 10 Nm (7 ft. lbs.).





26. Connect the ground cable to the camshaft cover.





27. Connect the crankcase ventilation hose to the camshaft cover.
28. Fit the ignition coils.
Tightening torque 8 Nm (6 ft. lbs.).
29. Fit the wiring harness to the intake manifold and the oil filter housing.





30. Fit the cable duct and bracket to the camshaft cover.
31. Connect the hose to the wastegate and solenoid valve.





32. Plug in the A/C pressure sensor connector, the connector to the coolant temperature sensor, the engine control module, the wastegate solenoid valve, the throttle body, the manifold absolute pressure sensor, the barometric pressure sensor, the IDM module and the ground cable on the engine control module.
33. Plug in the ignition coil connectors. Make sure the cables are position correctly so that they are not pinched by the cover. Plug in the connectors to the turbocharger solenoid valve and attach the cable clips.





34. Fit the cover over the ignition coils.





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





36. Connect both fuel lines to the fuel rail while gripping the lower nut. Use new seals.
Tightening torque 10 Nm (7 ft. lbs.).
37. Fit the air cleaner casing and connect the intake hose. Fit the air cleaner.





Important: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.

38. Fit the air cleaner cover. Plug in the mass air flow sensor connector and fit the turbocharger inlet pipe. Connect the hoses to the turbocharger inlet pipe.





39. Fit the turbocharger hose to the throttle body and the turbo delivery pipe.





40. Raise the car and remove 83 96 152 Engine centring tool kit from the subframe.





41. Tighten the rear torque arm bolts.
Tightening torque 70 Nm + 90° (52 ft. lbs. + 90°)





42. Fit the bolts on the power steering pipe clamps on the subframe.





43. Connect the positive starter motor cable.





44. Fit the stay between the intake manifold and the cylinder block.
Tightening torque 22 Nm (16 ft. lbs.).
45. Fit the oil return pipe to the turbocharger. Use a new gasket and a new O-ring.
Tightening torque 15 Nm (11 ft. lbs.).





46. Fit the stay between the exhaust manifold and the cylinder block.
Tightening torque 22 Nm (16 ft. lbs.).
47. Fit the turbocharger coolant pipe with new seals.
Tightening torque 40 Nm (30 ft. lbs.).
48. Lift up the catalytic converter, position its bracket to the studs on the engine block and position the catalytic converter to the turbocharger connection.





49. Insert the catalytic converter bracket bolts into the engine block and new nuts on the studs.
50. Lower the car and fit the catalytic converter with new nuts so that it fitted evenly on the turbocharger. Use 30 20 971 Screw-thread paste on the studs.
Tightening torque 25 Nm (18 ft. lbs.).
51. Raise the car and tighten the catalytic converter bracket nuts and bolts.
Tightening torque 25 Nm (18 ft. lbs.).
52. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the lower oxygen sensor. Make sure the cables are not twisted or damaged.
Tightening torque 40 Nm (30 ft. lbs.).
53. Fit the heat shield over the catalytic converter.





54. Fit the heat shield over the steering gear.
55. Clean the pipe connections, fit a joint clamp on the front pipe.
56. Fit the front exhaust pipe to the catalytic converter. Use a new gasket and new nuts.
Tightening torque 25 Nm (18 ft. lbs.).





57. Adjust the joint clamp so that the pipe ends are in the middle. Tighten the joint clamp nuts.
Tightening torque 40 Nm (30 ft. lbs.).
58. Fit the lower turbocharger delivery pipe.





59. Connect the hose to the headlamp washers. Fit and plug in the connector. Fit the lower spoiler shield. CV: Fit Chassis reinforcement, front supporting frame, CV





60. Lower the car slightly and fit the right wing liner and front right wheel. See wheels.





61. Lower the car a little more, lubricate threads sparingly with 30 20 971 Screw thread paste and fit the upper oxygen sensor.
Tightening torque 40 Nm (30 ft. lbs.).





62. Fit the turbocharger oil delivery pipe. Use new seals and grip the pipe so that it does not rotate.
Tightening torque 22 Nm (16 ft. lbs.).
63. Plug in the connectors for the oxygen sensors.





64. Fit the heat shield over the turbocharger.
65. Connect the negative battery cable and fit the battery cover.





66. Check the oil level and top up as necessary.
67. Fill with coolant and bleed the cooling system.
68. Remove the wing covers and restore the car's electrical functions.
69. Fit the upper engine cover.
70. Carry out After fitting a control module.