To Fit
To fit1. Undo each bolt for the fixed balancer shaft and timing chain guides separately and replace with the new bolt. Tighten each bolt before undoing the next one.
Tightening torque 10 Nm (7 lbf-ft).
2. Undo each bolt for the upper balancer shaft chain guide separately and replace with the new bolt. Tighten each bolt before undoing the next one.
Tightening torque 10 Nm (7 lbf-ft).
3. Remove the balancer shaft chain tensioner
4. Check that the chain tensioner piston is in the correct position. If the piston can be fully pushed in then it is aligned incorrectly and must be turned 180°.
5. Turn the piston on the balancer shaft chain's chain tensioner 90°, press it in and turn back 90°. Secure the tensioner with a wire clip or similar in the hole on the top side of the tensioner.
6. Fit the chain tensioner and remove the wire clip.
Tightening torque 10 Nm (7 lbf-ft)
7. Fit the timing chain tensioner.
Tightening torque 63 Nm (46 lbf-ft)
8. Fit the pin, the spring and the plug to the chain tensioner.
Tightening torque 22 Nm (16 lbf-ft)
9. Clean any remaining sealant from the timing cover sealing surfaces. Use the recommended degreasing agent.
10. Apply a bead of 90 297 970 Flange sealant about 2 mm thick along the middle of the sealing surfaces and around the bolt hole and oilways as illustrated or apply the flange sealant to the corresponding surfaces on the timing cover. Dab a small amount of 83 95 691 Silicone flange sealant in the joints between the cylinder head and the cylinder block.
11. Fit the timing cover by carefully twisting it in place. Use a pry bar and place a wood block between the bar and the cylinder head. Move the engine to the left and raise and lower respectively to fit the timing cover and the bolts.
Note
Make sure the cover does not catch on the cylinder head gasket. Move the gasket away with a screwdriver or feeler gauge.
Tightening torque 22 Nm (16 lbf-ft)
12. Fit the oil pump driver.
13. Make sure that the marking on the oil pump gear ring is turned outward and pump impeller with flange inward. Use a new 0-ring, grease with Vaseline.
14. Oil and fit the pump impellers and fit the pump cover in the correct position using the guide arrows and guide pin.
15. Fit the circlip with the bevelled edge face out and the opening pointing down.
16. Fit the bolt to the intermediate shaft's bearing bracket.
Tightening torque 22 Nm (16 lbf-ft)
17. Fit the bolt to the AC compressor bracket.
Tightening torque 40 Nm (30 lbf-ft)
18. Press out the generator adjuster sleeve slightly and fit the generator mounting and the generator.
Tightening torque, generator 47 Nm (35 lbf-ft)
Tightening torque, generator bracket 24 Nm (18 lbf-ft)
19. Fit the belt tensioner.
Tightening torque 59 Nm (44 lbf-ft)
20. Man: Fit the torque rod mounting and ground cable.
Tightening torque 47 Nm (35 lbf-ft)
21. Fit the left-hand engine pad. Centre the engine pad on the marks made earlier.
Tightening torque, bolts 40 Nm + 45° (35 lbf-ft + 45°)
Tightening torque, nut 84 Nm (62 lbf-ft)
22. Fit the electrical centre
23. Lower the engine on the wedges at the oil filter adapter and the drive shaft universal joint. Remove the lifting eye.
24. Fit the crankshaft pulley.
Tightening torque 175 Nm (129 lbf-ft)
25. Clean any coolant spilled on the A/C compressor bracket.
26. Apply non-acidic Vaseline on the seals and fit the connection sleeve to the cylinder block. Clean the seat in the cylinder block.
27. Fit the coolant pump.
Tightening torque 22 Nm (16 lbf-ft)
28. Fit the coolant pipe on the coolant pump and on the turbo. Use new seals.
Tightening torque, banjo screw, turbocharger 25 Nm (18 lbf-ft)
Tightening torque, banjo screw, coolant pump 20 Nm (15 lbf-ft)
29. Fit both the longitudinal coolant pipes to the coolant pump with a new 0-ring.
Tightening torque 10 Nm (7 lbf-ft).
30. Fit both longitudinal coolant pipes to the cylinder block.
31. Fit the hose clips and the hoses on the coolant pump inlet.
32. Fit the fan cowling. Attach the connector and hose clips. Fit the upper coolant hose.
Aut: Fit the bolt for the oil cooler pipe.
33. Fit the bracket for the power steering pump and the power steering pump.
Tightening torque 24 Nm (18 lbf-ft)
34. Fit the turbocharger delivery pipe hose to the turbo intake pipe and fit the intake manifold to the turbo with a new 0-ring.
35. Fit the engine's lifting eye.
36. Fit the poly-V-belt in accordance with the indicated rotation direction.
37. Fit the mass air flow sensor with hose and connector.
38. Fit the right-hand engine mounting.
Tightening torque 47 Nm (35 lbf-ft)
39. Fit the engine mounting bracket. Do not fit the nut yet.
Tightening torque, bolts 47 Nm (36 lbf-ft)
40. Fit the crankcase ventilation pipe.
41. Fit the connector to the turbo solenoid valve.
42. Raise the car and remove the flywheel locking attachment.
43. Clean and degrease the sealing surfaces and apply an even bead of 90 297 970 Flange sealant about 2 mm thick on the oil sump sealing surface.
44. Make sure the pipe to the oil adapter is fitted securely and that it is aligned correctly in the oil sump. Fit the oil sump.
45. Tighten the oil sump bolts.
Tightening torque 22 Nm (16 lbf-ft)
46. Fit the hose to the crankcase ventilation.
47. Fit the generator's electrical connections
48. Fit the protective cover to the gearbox.
49. Fit the rear engine mounting to the gearbox.
Tightening torque 60 Nm + 60° (44 lbf-ft + 60°)
50. Connect the oil pipe with new 0-rings.
51. Fit the front exhaust pipe to the turbo with new nuts. Lubricate with 90 513 210 Universal paste.
Tightening torque 22 Nm (16 lbf-ft)
52. Fit the torque arm.
Tightening torque, lead-through bolt 90 Nm + 90° (66 lbf-ft + 90°)
Tightening torque, bracket 70 Nm + 90° (52 lbf-ft + 90°)
53. Lower the car and fit the washer and nut on the right-hand engine pad.
Tightening torque 105 Nm (78 lbf-ft)
54. Fit and tighten the nuts on the exhaust pipe flange and plug in the oxygen sensors. Fasten the cable with cable ties.
Tightening torque 22 Nm (16 lbf-ft)
55. Fit the turbocharger heat shield.
56. Fit the by-pass valve with pipe.
57. Man: Connect the gear linkage to the selector rod.
58. Man: Undo the gear lever gaiter with frame from the centre console. Engage 4th gear and insert 87 92 632 lock pin into the gear lever housing. Tighten the clamp on the gear linkage.
Tightening torque 22 Nm (16 lbf-ft)
59. Man: Remove the lock pins, check the gear positions and that the ignition key can be removed. Insert the plastic plug into the gearbox. Fit the gear lever gaiter.
60. Fit the battery tray and the battery. Fit the battery cover. Connect the battery cables.
61. Fit the upper engine cover.
62. Raise the car and fit the spoiler shield.
63. Fit the right-hand wing liner.
64. Fit the headlamp position sensor (option). Fit the drive belt cover.
65. Fit the right-hand wheel. See WIS - Wheels and tires - Wheels.
Tightening torque 110 Nm (81 lbf-ft)
66. Pressure test the cooling system.
67. Fill with new coolant and close the expansion tank cap.
68. Fill with engine oil.
69. Set the cars clock and date.
70. Calibrate the AC system by pressing in the AUTO and OFF buttons at the same time.
71. Start the engine and make sure there are no leaks.
72. US: After completing these measures, mark the bolt with white paint as illustrated in the introduction.