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Valve gear, to fit (in car)

Valve gear, to fit (in car)


1. Fit the valve stem seal to the valve. Use Assembly tool for valve stem seal part no. 83 95 071 and a plastic mallet to carefully tap the seal into position.


2. Fit the spring and spring cap and place the collets in the spring cap groove.

3. Fit the valve cones with Valve spring compressor , part no. 83 95 246.

4. Disconnect the compressed air, remove the air nipple and the flywheel locking segment.


5. Fit the spark plugs using spark plug socket 83 95 485.

Tightening torque: 25 Nm (18.5 lbf ft).

6. Remove the protective sleeves and fit the valve tappets.

7. Rotate the crankshaft to 60° BTDC

8. 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)

Important

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.

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.


9. 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)

10. Fit the ignition discharge module.

11. Fit the inner (rear) timing cover.


12. Fit the camshaft sprockets correctly in relation to the locating pins.

Tightening torque: 50 Nm (37 lbf ft) + 60°

13. Fit the coolant pump.


Tightening torque: 25 Nm (18.5 lbf ft).

14. Fit the bracket with tensioning roller and the upper adjuster roller.

15. Fit Adjustment tools for cam sprocket and timing belt KM-800-1 on no. 1 and no. 2 camshaft sprockets and KM-800-2 on no. 3 and no. 4 camshaft sprockets.


16. 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.


17. Refitting a marked timing belt: Fit the timing belt in accordance with the marking on the belt and the marked direction of rotation. Use 83 95 006 Adjustment tools, cam sprocket and timing belt, V6 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 marking on the belt and the marked direction of rotation. Use 83 95 006 Adjustment tools, cam sprocket and timing belt, V6 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 the locking tool KM-800-10.

Tightening torque, guide roller, 40 Nm (30 lbf ft)

18. 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 sprockets 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

19. 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 sprockets are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprockets.

Important

Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.


20. Fit the lower intake manifold with new gaskets.


Tightening torque: 20 Nm (15 lbf ft)

21. Fit the middle intake manifold.

Tightening torque: 20 Nm (15 lbf ft)

22. Fit the upper intake manifold with a new gasket.


Tightening torque: 20 Nm (15 lbf ft)

23. Connect the fuel lines.

24. Plug in the connectors for the ignition discharge module and injectors.

25. 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 torques:

Bypass pipe 8 Nm (6 lbf ft)

26. Connect the vacuum hoses and plug in the pressure sensor's connector for the upper intake manifold.

27. Refit the throttle cable.

28. Fit the crankshaft pulley.


Tightening torque: 20 Nm (15 lbf ft)

29. Fit the timing cover.

Tightening torque: 8 Nm (6 lbf ft)

30. Fit the belt tensioner and the generator air intake.

31. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.

32. Fit the multigroove belt.

33. Tighten the retaining bolts on the pulleys.

Tightening torques:

Belt pulley/coolant pump: 8 Nm (6 lbf ft)

Belt pulley/power steering pump: 20 Nm (15 lbf ft)

34. Fit the right-hand engine attachment with bracket and engine mount.


Tightening torques:

To body 63 Nm (46.5 lbf ft)

35. Fit the power steering hose in the holder

36. Fit the mass air flow sensor with hose.

37. Raise the car.

38. Lower the engine by carefully removing the wedges.


39. Lower the car to the floor.

40. Reconnect the negative cable to the battery.

41. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.

42. 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.

Note

The A/C should be OFF.


43. Raise the car.

44. Check for leakage.

45. Fit the lower spoiler sections.


46. Lower the car to the floor.

47. Fit the engine cover and remove the wing protectors.

48. Reset the clock and the radio, if fitted.