Fitting the cylinder head (in car)
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Fitting the cylinder head (in car)
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1.
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Carefully clean all the sealing surfaces, rotate the crankshaft 45˚ and fit the cylinder head. Make sure it is correctly seated on the guide sleeves and that the chain runs freely.
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2.
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Fit and tighten the cylinder head bolts.
The tightening sequence is shown in the illustration.
Tighten in three stages:
Step I: 40 Nm (29.5 lbf ft)
Step II: 60 Nm (44.3 lbf ft)
Stage III: Angle tighten 90˚
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3.
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Fit the two bolts between the timing cover and cylinder head.
Tightening torque: 24 Nm (17.7 lbf ft)
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4.
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Make sure the camshafts are aligned with their setting marks and rotate the crankshaft back to its 0-marking.
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5.
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Fit the camshaft sprockets and chain. Start with the intake camshaft.
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Note
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Do not tighten the bolts.
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6.
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Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
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7.
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Fit the chain tensioner with a 27 mm socket.
Tightening torque: 63 Nm (47 lbf ft)
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8.
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Fit the chain tensioner plug with push rod and spring.
Tightening torque: 22.5 Nm (16.6 lbf ft)
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9.
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Make sure the chain is positioned correctly on the chain guards. Rotate the crankshaft two revolutions and check the setting of the flywheel and camshafts.
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10.
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Tighten the camshaft sprocket bolts.
Tightening torque: 63 Nm (47 lbf ft)
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11.
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Clean the sealing surface of the camshaft cover with benzine.
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12.
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Apply soap to the opening in the camshaft cover and fit the cover, starting at the opening. Then, tighten the bolt located furthest to the front at the timing chain end. Continue all the way round the outside and inside.
Tightening torque: 15 Nm (11 lbf ft)
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13.
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Fit the spark plugs.
Tightening torque: 28 Nm (20.7 lbf ft)
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14.
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Fit the ignition discharge module (turbo), or alternatively the ignition leads, distributor cap and cover.
Tightening torques:
Ignition discharge module: 11 Nm (8 lbf ft)
Cover: 4 Nm (3 lbf ft)
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15.
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Position the intake manifold gasket using guide pins, part no. 83 94 736, and fit the intake manifold.
Tightening torque: 24 Nm (17.7 lbf ft)
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16.
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Tighten the bolts on the intake manifold stay. Start with the one in the cylinder block. Connect the temperature sensor electrical connection.
Tightening torque: 24 Nm (17.7 lbf ft)
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17.
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Tighten the bolts securing the water pipe to the thermostat housing cover and connect the hose for the throttle body preheating.
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18.
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Replace the lifting eye and the bracket for the electrical connections.
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19.
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Connect the crankcase and vacuum hoses to the camshaft cover and fit the dipstick pipe and bracket.
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20.
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Plug in the ignition discharge module (turbo) and fit the water pipe for the turbocharger cooling.
Tightening torque: 25 Nm (18.5 lbf ft)
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21.
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Connect the coolant hoses to the cylinder head.
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22.
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Tighten the lock nuts on the front exhaust pipe or, alternatively, the turbocharger. Tighten the bolts on the turbocharger stay. Start with the bolt in the cylinder block.
Tightening torques:
Lock nuts: 25 Nm (18.5 lbf ft)
Turbo, stay to block: 22 Nm (16.2 lbf ft)
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23.
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Fit the crankcase ventilation pipe together with the intake manifold (turbo).
Tightening torques:
Turbo/intake manifold: 8 Nm (5.9 lbf ft)
Crankcase ventilation pipe: 24 Nm (17.7 lbf ft)
Pipe clamp: 9.5 Nm (7 lbf ft)
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24.
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Fit the power steering pump and replace the belt pulley. Mount the belt and check the position of all the belt pulleys.
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25.
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Relieve the belt tensioner with a ratchet handle extension and remove the drill.
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Important
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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.
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26.
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Fit the pressure pipe between the charge air cooler and the throttle body (turbo). Fit the heat shield (turbo).
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27.
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Fit the intake and bypass hoses (turbo).
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28.
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Fit the air cleaner. Replace the intake hose and connect the mass air flow sensor (B204i).
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29.
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Connect the negative cable on the battery and make sure the radiator drain plug is tight. Fill with coolant and check for leaks.
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30.
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Start the engine and warm it up until the thermostat opens. Turn off the engine and check the coolant and oil levels, top-up if necessary.
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31.
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Fit the engine cover or, alternatively, the resonator, remove the wing covers and make sure the engine bay is clean.
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32.
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Start the engine and check all functions. Drive the car on test.
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