Part 2
Cylinder head/gasket, replacement (Continued)
Cleaning
Use emery cloth 951 1024 to clean the shaft journal and mating surface.
Note! Clean in the direction around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other impurities are completely removed before the new seal ring is installed.
Installing the front camshaft seals
Lubricate the surface of the seal that the camshaft rotates against.
Install the camshaft seal. Use drift 999 5718 Drift 999 5718 Drift.
Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out
Checking crankshaft setting
Turn the crankshaft counter-clockwise until it stops against the adjustment tool.
Check that the marking on the crankshaft timing gear pulley corresponds to the marking on the oil pump.
Installing VVT-unit/timing gear pulley on exhaust camshaft
Note! The section "Installing the VVT-unit/timing gear pulley" described here is to make sure that the VVT-unit is positioned correctly and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later troubleshooting.
Loosen, do not remove the screws that hold the timing gear pulley to the VVT-unit.
Press the VVT-unit/ timing gear on the camshaft.
Install the center screw that holds the VVT-unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit counter-clockwise as far as it will go.
Remove the center screw.
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the end-position. Continue turning clockwise until the timing gear pulley's marking is 1 tooth before the marking on the upper timing gear casing.
Note! Do not turn counter-clockwise during this procedure.
Check that the timing gear pulley is still in its end-position at the oval holes.
Tighten the VVT-unit's centre screw according to Tightening torque Tightening Torque.
Check that the VVT-unit does not rotate when tightening.
Install the centre plug. Tighten according to Tightening torque Tightening Torque.
Turn the variable valve timing unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.
Installing the variable valve timing (VVT) unit on the intake camshaft
Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit.
Press the variable valve timing unit / timing gear onto the camshaft.
Install the centre screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit counter-clockwise as far as it will go.
Remove the center screw.
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the end-position. Continue turning clockwise until the timing gear pulley marking is 1½ teeth before the marking on the upper timing gear casing.
Note! Do not turn counter-clockwise during this procedure.
Check that the timing gear pulley is still in its end-position at the oval holes.
Tighten the centre screw in the VVT unit. See Tightening torque Tightening Torque.
Check that the VVT-unit does not rotate when tightening.
Install and tighten the centre plug according to Tightening torque Tightening Torque.
Turn the variable valve timing unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.
Finishing
Tighten the centre screw for the timing belt tensioner. Tighten to 5 Nm.
Installing the timing belt
Tighten the centre screw on the belt tensioner with 5 Nm.
Install the belt as follows:
- crankshaft
- the idler pulley
- intake cam
- exhaust cam
- water pump
- tension pulley.
Note! The VVT-units do not have a return spring and are easily dislodged when installing the timing belt. Check that the markings match.
Adjusting timing belt
This adjustment is carried out on a cold engine where a suitable temperature is approx. 20°C/68°F.
At a higher temperature, for example, with a warm engine or a higher ambient temperature, the needle assumes a position farther to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Hold the center screw secure and turn the eccentric on the belt tensioner counter-clockwise until the tensioner's indicator passes the marked position.
Tighten the screws on the timing gear pulley for the exhaust camshaft according to Tightening torque Tightening Torque.
Tighten the 3 screws on the intake camshaft timing gear pulley. Tighten. See Tightening torque Tightening Torque.
Adjusting the timing belt
Note! Check that the VVT-units are in their end-position.
Turn the eccentric back so that the indicator reaches the marked position in the centre of the window. Remember to hold the centre screw secure at the same time.
Hold the eccentric secure and tighten the centre screw according to Tightening torque Tightening Torque.
Check that the indicator is in the correct position.
Remove:
- camshaft adjustment tool 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool.
- crankshaft stop 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool. Install the plug with new sealing washer. Tighten according to Tightening torque Tightening Torque.
Checking the markings and belt tension
Press on the timing belt to check that the indicator on the tensioner moves easily.
Install the upper timing belt cover.
Turn the crankshaft two revolutions and check that the markings on the crankshaft's and camshafts' gear pulleys match.
Check that the indicator on the belt tensioner is within the marked position.
Remove the upper timing cover.
Installing components
Install:
- the trigger wheel. Tighten the screw
- the camshaft position (CMP) sensor housing. Tighten the screws
- the lower and upper torque rod bracket on the cylinder head. Tighten according to Tightening torque Tightening Torque.
Install:
- screw for the inner timing gear casing
- front timing cover
- the cable duct to the mountings on the right suspension turret
- the auxiliaries belt
- the expansion tank
- the servo oil reservoir
- the bleed hose to the expansion tank. Tighten the clamp.
Check that the hoses are correctly positioned.
Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.
Install:
- the starter motor
- union screw for water-heated crankcase ventilation at the cylinder head's trailing edge. Use new sealing washers and tighten down.
- the camshaft position sensor (CMP) housing and trigger wheel
- the lower engine stabilizer brace bracket in the cylinder head
- the upper engine stabilizer brace
- bracket for hoses on lower torque rod bracket.
Install:
- the bracket/lifting eye for the torque rod bracket
- the ignition coils and ground terminals according to earlier markings. Connect the connector for the variable valve timing solenoid
- the clamp for the positive lead at the lifting eyelet bracket
Installing intake manifold
Clean the intake manifold gasket face to the cylinder head.
Install a new gasket on the cylinder head. Secure with the two screws in the lower row.
Lower the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.
Note! Take care not to damage the fuel pressure pipes.
Route crankcase ventilation hose between cylinder 2 and 3.
Install:
- the union screw for the crankcase ventilation on the underside of the intake manifold. Use new sealing washers. Tighten according to Tightening torque Tightening Torque.
- the rest of the screws holding the intake manifold to the cylinder head. Tighten according to Tightening torque Tightening Torque
- the hose to the canister purge (CP) valve
- the control hose for the turbo's overflow valve
- the brake vacuum hose
- the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
- the cover over the ignition coils
- the upper timing cover
- the upper engine coolant hose for the engine and radiator. Tighten the clamp
- the screw holding the dip stick pipe to the intake manifold. Connect the connector to the electronic throttle module (ETM)
- the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.
Installing the fuel rail
Install:
- the fuel rail. Use new screws. Press the quick-release connector for the fuel pressure line until it clicks. See Fuel line, lock Service and Repair
- clamp for the injectors' wiring at the cylinder head's trailing edge. Plug in connectors for injectors and fuel pressure sensor as well as water temperature sensor.
Install:
- the protective cover over the injector connectors
- the charge-air pipe over the engine. Tighten the pipe using the three screws by the engine. Tighten the clamps
- fresh air hose between turbo and air filter
- air filter assembly with mass air flow sensor. Plug in connector for mass air flow sensor and tighten the clamp.
- the inlet hose between the air filter and the front cover plate
Installing components
Raise the car. Install:
- the union screw that holds the turbocharger's oil pressure pipe to the engine. Use new sealing washers. Tighten according to: Tightening torque Tightening Torque
- the turbocharger's oil return line. Use a new gasket and sealing ring. Tighten according to: Tightening torque Tightening Torque
- the clamp between the oil pressure pipe and the oil return line. Tighten the three nuts that hold the front exhaust pipe to the turbocharger according to: Tightening torque Tightening Torque.
- the lower screw for the heat deflector plate over the turbocharger (TC)
- the splash guard under the engine. (Only applies to cars with automatic transmission)
- the plastic nuts for the hatch in the right wing liner
- right front wheel. See Installing wheels Service and Repair.
Lower the car.
Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. See Tightening torque Tightening Torque.
Install:
- the ground strips between the cylinder head and the firewall
- the engine stabilizer brace between the suspension turrets Clamp the servo hose at the right-hand engine stabilizer brace mounting
- battery's minus cable. First read: Battery, disconnecting Battery Disconnecting
Fill up engine with coolant.
Check
Change the oil and replace the oil filter as necessary.
Check:
- the engine oil level
- the servo oil level
- the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks.
Top up the coolant if necessary.