Fitting of Cylinder Head (In Car)

Cylinder Head
Fitting Of Cylinder Head (in car)
1. Fit the inner gasket for the camshaft cover partition with 46 20 084 Ultra fast adhesive.
2. Position the gasket between the intake manifold and intermediate partition by means of two straps.

Cylinder Head Tightening Sequence:

3. Carefully clean all sealing surfaces. Apply a 2 mm thick and 10-20 mm long bead of 93 21 795 Flange sealant to the inner part of the upper contact surface of the timing cover (against the cylinder head).
Turn the engine in the stand, turning the crankshaft 45° to lower the pistons.
Fit a rubber band round the chain guides and mount the cylinder head with a new gasket. Check that it is correctly seated on the locating sockets and that the chain is not trapped.
4. Fit the cylinder head Torx bolts and tighten to torque
Tightening torque in three stages
^ Step I: 40 Nm (30 ft. lbs.)
^ Step II: 60 Nm (44 ft. lbs.)
^ Step III: Tighten a further 90°
Tightening sequence for the cylinder head bolts as shown.






5. Fit the two bolts between the timing cover and cylinder head.
Tightening torque 22 Nm (16 ft. lbs.)
6. Check that the camshafts are in line with their timing marks and reset the crankshaft in line with the 0 mark.
7. Fit the camshaft sprockets and chain. Start with the camshaft on the exhaust side.

Note: Do not tighten the bolts yet!






8. Prepare the chain tensioner for fitting by pressing down the catch and pushing in the chain tensioner.
9. Fit the chain tensioner, using a 27 mm socket.
Tightening torque 63 Nm (47 ft. lbs.)
10. Fit the chain tensioner plug with push rod and spring.
Tightening torque 22 Nm (16 ft. lbs.)
11. Tighten the bolt on the idler pulley.
Tighten the camshaft sprocket bolts. Hold the end of the camshaft with a spanner.
Tightening torque 63 Nm (47 ft. lbs.)
12. Check that the chain is correctly seated in the guides.
Rotate the crankshaft two complete turns and check the settings of the crankshaft pulley and camshafts.
13. Clean the sealing surface of the camshaft cover with benzene.






14. Coat the opening in the camshaft cover thinly with oil and fit the cover, starting at the opening.
Make sure that the cables at the edge of the cover against the intake manifold do not get trapped.
Then tighten the bolt located furthest to the front at the timing chain end.
After that, continue all the way round on both the inside and outside.
Tightening torque 15 Nm (11 ft. lbs.)
15. Fit the spark plugs.
Tightening torque: 28 Nm (21 ft. lbs.)
Fit the ignition discharge module.
Tightening torque: 11 Nm (8 ft. lbs.)
16. Fit the intake manifold with intermediate partition but do not tighten until the straps are cut off and pulled away.






17. Tighten the intake manifold, using a torque wrench.
Tightening torque 22 Nm (16 ft. lbs.)






18. Fit the generator bracket.
Make sure that the adjuster sleeves in the generator bracket are tapped out approx. 1 mm to facilitate fitting.
Fit the belt tensioner.






19. Tighten the bracket for the ignition discharge module connector in the rear lifting eye and the coolant pipe fitting.
20. Fit the bolt securing the coolant pipe to the thermostat housing cover.
21. Connect the coolant hoses to the cylinder head.
22. Plug in the ignition discharge module and temperature sensor connectors.






23. Fit the turbocharger retaining nuts between the exhaust manifold and the turbocharger and tighten to torque.
Tightening torque: 25 Nm (19 ft. lbs.)
24. Fit the heat shield over the turbocharger.
25. Insert the dipstick tube.
26. Raise the car.
27. Tighten the turbocharger steady bar retaining bolts.






28. Tighten the intake manifold steady bar retaining bolts.
Fit the dipstick tube correctly in position.
29. Lower the car to the floor.






30. Fit the fuel hoses and refit the rubber protectors.
31. Fit the crankcase ventilation nipple on the valve cover.
32. Tighten the dipstick tube, attach the throttle cable and adjust as necessary.
Fit the ground connections to the cylinder head.
Fit the cover over the throttle body spindle.
33. Fit the servo pump. Fit the multigroove belt and check the position of all pulleys.
Tightening torque 20 Nm (15 ft. lbs.)






34. Release the tension of the belt tensioner using 83 95 254 Drawbar handle, hydraulic belt tensioner and remove the allen key.






35. Fit the lifting eye, press the rubber in position and plug in the solenoid valve connector.
36. Fit the charge air pipe and bypass valve.
Connect the bypass valve vacuum hose and the pressure/temperature sensor connector.
37. Fit and connect the mass air flow sensor's rubber gaiter.
38. Fit the engine mounting with yoke and the servo pump pipe bracket and tighten them, using a torque wrench.
Tightening torque bolts 47 Nm (39 ft. lbs.)
Tightening torque nut 105 Nm (78 ft. lbs.)
39. Remove the wedge and secure the servo pump pipe to the subframe.
40. Fit the right-hand front wheel.
41. Fit the crankcase breather pipe.
Tightening torque banjo connection: 24 Nm (18 ft. lbs.)
Tightening torque, mounting against camshaft cover 11 Nm (8 ft. lbs.)
42. Connect the negative battery cable. Check that the radiator's drain plug is properly tightened. Top up with coolant and check the system for leaks.
43. Check the coolant and oil levels. Top up if necessary.
44. Remove the protective covers from the wings and check that the engine bay is clean.
45. Lower the car to the floor.
46. Bleed the cooling system as follows.
47. Fill with coolant. Do not forget to shut the drain cock on the radiator first. Refer to Coolant for mixtures. Close the cap.
48. Start the engine and run it warm with the heater control on MAX.
49. Check the coolant level. Top up if necessary.
50. Check all functions.
Test drive the car.
51. Reset the clock and radio code.
Calibrate the ACC.