Valve gear, to fit (in car)
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Valve gear, to fit (in car)
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2.
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Fit the spring and spring cap and place the collets in the spring cap groove.
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4.
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Disconnect the compressed air line, remove the compressed air adapter and the flywheel locking segment.
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5.
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Fit the spark plugs using spark plug socket 83 95 485.
Tightening torque: 25 Nm (18.5 lbf ft).
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6.
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Remove the protective sleeves and fit the valve tappets.
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7.
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Rotate the crankshaft to 60° BTDC
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8.
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Place the camshafts in position and fit the stuffing boxes and bearing caps. Start where the cams point downwards and load the tappets. Coat the cylinder head contact surfaces of the front bearing caps sparingly with part No. (10) 74 96 268, see illustration.
Cylinders 1-3-5 (rear)
The locating pin on the camshafts should point towards the inside bolts for the camshaft bearing caps.
Cylinders 2-4-6 (front)
The locating pin for the intake camshaft should be in line (downwards) with the inside bolts for the camshaft bearing caps.
The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head.
Tightening torque: 8 Nm (6 lbf ft)
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Important
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Tighten the bolts in stages - 1/2 to 1 turn at a time. The markings on the camshaft bearing caps and the cylinder head must match.
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The caps marked L1-L8 are for the cylinder head with cylinders 1-3-5 and the caps marked R1-R8 are for the cylinder head with cylinder 2-4-6. The camshaft bearing seats in each cylinder head are numbered 1-8.
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9.
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Check that the O-rings are in place in the camshaft cover and wipe clean. Lubricate with a soap solution and place part No. (10) 81 52 381 in the corners at the camshaft bearing caps. Fit the camshaft cover.
Tightening torque: 8 Nm (6 lbf ft)
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10.
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Fit the ignition discharge module.
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11.
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Fit the inner (rear) timing cover.
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12.
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Fit the camshaft sprockets correctly in relation to the locating pins.
Tightening torque: 50 Nm (37 lbf ft) + 60°
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13.
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Fit the coolant pump.
Tightening torque: 25 Nm (18.5 lbf ft).
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14.
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Fit the bracket with tensioning roller and the upper adjuster roller.
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16.
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Rotate the crankshaft to just before the 0° mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
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17.
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Refitting a marked timing belt:
Fit the timing belt in accordance with the marking on the belt and the marked direction of rotation. Use
Adjustment tools for cam sprocket and timing belt
KM-800-30 in order to hold the belt in place. Fit the lower guide roller. Make sure that the washer is fitted correctly. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30.
Fitting a new unmarked timing belt:
Fit the new timing belt in accordance with the belt's direction of rotation. Use
Adjustment tools for cam sprocket and timing belt
KM-800-30 in order to hold the belt in place. Fit the lower tension pulley. Make sure that the washer is fitted correctly. Remove the tool KM-800-30.
Fit locking tool KM-800-10, position a piece of timing belt and fit
Belt tension meter
part no. 83 93 985 to measure the belt tension.
Tighten the centre bolts of the adjuster rollers lightly. Adjust the lower adjuster roller anticlockwise until a tension of 275-300 Nm is obtained. Use tool 83 94 983. Tighten the adjuster roller's bolt. Use
Installation tool for camshaft sprockets and camshaft drive belt
83 94 983 as a counterstay. Check the belt tension again and adjust as necessary.
Tightening torque: 40 Nm (30 lbf ft)
Remove the belt tension gauge and the piece of the timing belt
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Important
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Adjustment of belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.
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18.
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Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tension pulley with a 5 mm Allen key until the two lines on the tension pulley correspond with each other. Tighten.
Tightening torque: 20 Nm (15 lbf ft)
Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprocket are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay.
Tightening torque: 40 Nm (30 lbf ft)
Remove KM-800-20 and the other locking tools
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19.
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Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
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Important
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Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
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20.
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Fit the lower intake manifold with new gaskets.
Tightening torque: 20 Nm (15 lbf ft)
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21.
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Fit the middle intake manifold.
Tightening torque: 20 Nm (15 lbf ft)
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22.
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Fit the upper intake manifold with a new gasket.
Tightening torque: 20 Nm (15 lbf ft)
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23.
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Connect the fuel lines.
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24.
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Plug in the connectors for the ignition discharge module and injectors.
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25.
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Connect the vacuum hose and the two water hoses to the throttle. Fit the turbo pressure hose with charge air bypass pipe. Plug in the throttle connector and connect the hose to the venting valve on the underside of the throttle.
Tightening torque:
Bypass pipe 8 Nm (6 lbf ft)
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26.
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Connect the vacuum hoses and plug in the pressure sensor's connector for the upper intake manifold.
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27.
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Refit the throttle cable.
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28.
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Fit the crankshaft pulley.
Tightening torque: 20 Nm (15 lbf ft)
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29.
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Fit the timing cover.
Tightening torque: 8 Nm (6 lbf ft)
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30.
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Fit the belt tensioner and the generator air intake.
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31.
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Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
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32.
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Fit the multigroove belt.
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33.
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Tighten the retaining bolts on the pulleys.
Tightening torque:
Belt pulley/coolant pump: 8 Nm (6 lbf ft)
Belt pulley/power steering pump: 20 Nm (15 lbf ft)
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34.
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Fit the right-hand engine attachment with bracket and engine mount.
Tightening torque:
To body 63 Nm (46.5 lbf ft)
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35.
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Fit the power steering hose in the holder
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36.
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Fit the mass air flow sensor with hose.
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38.
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Lower the engine by carefully removing the wedges.
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40.
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Reconnect the negative cable to the battery.
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41.
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Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
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42.
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Bleed the cooling system as follows:
Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level.
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Note
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The A/C should be OFF.
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45.
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Fit the lower spoiler sections.
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47.
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Fit the engine cover and remove the wing protectors.
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48.
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Reset the clock and the radio, if fitted.
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