Installing Components When Replacing Valve Stem Seals
Install valve stem seals
Lubricate protective sleeve (1) and install it on the valve stem.
Lubricate valve stem seal (2). Press seal down and past the protective sleeve with fingers.
Pull off protective sleeve.
Press seal down by hand as far as it will go. Use drift 999 5379.
Install valve spring and spring washer.
Compress so that the 3 valve tracks are visible.
Note! Do not compress more than is absolutely necessary or damage may be caused to the valve stem seals.
Install valve locks. Check that valve locks are in the correct position when the spring is not loaded.
Continue working according to engine firing order: for B52xx = 1-2-4-5-3
Note! Set each cylinder to upper dead center before continuing working.
Cleaning cylinder head
Blow clean oil ducts for tappets in cylinder head.
Wipe clean cylinder head upper sealing surface and camshaft cover lower sealing surface using denatured alcohol.
Install tappets.
Note! The tappets must be installed in original order.
Lubricate tappets and bearing recesses for camshafts.
Apply liquid gasket, P/N 116 1059 on camshaft cover. Use roller 951 1205.
Note! Install new O-rings around the spark plug wells.
Lubricate bearing recesses for camshaft in camshaft cover.
Install the camshafts.
Secure front of camshafts using holder 999 5453/999 5508 and rear of camshafts using camshaft adjustment tool 999 5452 (without extensions).
Setting crankshaft position
Use camshaft blocker 999 5451.
Turn engine counter-clockwise until counter weight engages the blocker.
Check that the markings on the crankshaft timing gear pulley/oil pump housing correspond.
Install camshaft cover
Draw the cover down parallel with the cylinder head using 2 press tools 999 5454.
Torque the camshaft cover from the center outwards to 17 Nm (12.5 ft. lbs.).
Remove: 999 5453/999 5508 and 999 5454.
Install spark plugs, tighten to 25 Nm (18 ft. lbs.).
Installing new front camshaft seals
Use drift 999 5449.
Lubricate seal.
Carefully tap in seal.
Install timing belt
Position upper camshaft belt cover.
Install camshaft pulleys according to marking.
Screw 2 screws into place in each camshaft pulley until they act on the pulleys.
Note! Check that the screws are centrally positioned. See illustration
Remove upper camshaft belt cover.
Install timing belt.
Tighten timing belt
Install tensioner damping unit.
Remove lock pin from tensioner damping unit.
Press in new plastic washer.
Push forcefully or knock the belt twice with a hammer shaft in the direction of the arrow (1) and two times in the direction of the arrow (2).
Torque camshaft pulleys screws to 20 Nm (14.7 ft. lbs.).
Remove tool 999 5452 from rear of camshafts.
Remove crankshaft adjustment tool 999 5451.
Turn engine crankshaft 2 revolutions. Check that the marking corresponds.
Install
- protective plug with new gasket in crankshaft adjustment tool hole. Tighten to 40 Nm (30 ft. lbs.)
- starter motor, tighten to 40 Nm (30 ft. lbs.)
Install rear camshaft seal
Use drift 999 5450.
Lubricate seal.
Press in seal.
Note! The seal is usually positioned flush with the inner chamfer edge. If there are grooves on the shaft journal the seal can be pressed in a further 2 mm, by reversing the sleeve.
Install
- torque control arm, tighten to 45 Nm (33 ft. lbs. and angle-tighten 90°.
Tightening Engine Mounts (Part 2 Of 2):
- torque rod, tighten to 35 Nm (26 ft. lbs. and angle- tighten 90°
- torque control arm stay, tighten screws to 10 Nm (7.3 ft. lbs. and nut to 25 Nm (18 ft. lbs.
- trigger and Camshaft Position Sensor (CMP)
- rotor and distributor cap
- connect ignition cables
- Air Cleaner (ACL) housing assembly including intake pipe and hoses
- Turbocharger (TC) control valve (if applicable).
Install
- timing covers
- fuel rail. Lubricate injector O-rings with Vaseline. Remove holder 999 5533 and 999 5620 (from and including model year 199S).
- cover over ignition cables
- charge air pipe over engine (turbo charged engines only).
NOTE! Remove temporary seal.
- cover over throttle pulley
- the two ground strips
- battery negative lead to battery.
Reset clock and anti-theft radio code.
Function test
Test drive engine Check for leakage.