Fitting of cylinder head (in situ)
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Fitting of cylinder head (in situ)
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1.
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Thoroughly clean all the flange surfaces for the gaskets, rotate the crankshaft through 45° and fit the cylinder head. Make sure that it is correctly seated in the locating sockets and that the chain is not trapped.
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2.
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Fit the 10 torx bolts and
tighten them in three stages, as shown:
Stage I 40 Nm (30 lbf ft)
Stage II 60 Nm (44 lbf ft)
Stage III A further quarter-turn (90°)
Tightening sequence for cylinder head bolts.
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3.
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Fit the two bolts between the timing cover and the cylinder head.
Tightening torque: 22 Nm (16 lbf ft).
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4.
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Check that the camshafts are in line with their timing marks and that the 0° mark on the crankshaft is in line with the timing mark.
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5.
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Fit the camshaft sprockets and chain. Start with the camshaft on the inlet side.
Do not tighten the bolts yet.
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6.
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Prepare the chain tensioner for fitting by pressing down the catch and pushing in the chain tensioner.
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7.
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Fit the chain tensioner, using a 27 mm socket.
Tightening torque: 63 Nm (47 lbf ft).
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8.
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Fit the plug for the chain tensioner with push rod and spring.
Tightening torque: 22 Nm (16 lbf ft).
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9.
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Check that the chain is correctly seated in the guides. Rotate the crankshaft two complete turns and check that the timing marks on the flywheel and camshafts are still in alignment.
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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 flanges of the camshaft cover, using benzine.
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12.
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Apply soap to the open end of the camshaft cover and fit the cover, starting at the open end. Then tighten the bolt located furthest to the front at the timing end. Then continue all the way round, on both the inside and outside.
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 or the cover plate.
Tightening torque: 11 Nm (8 lbf ft).
Fit the ignition cables and distributor cap.
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15.
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Align the intake manifold gasket with the aid of guide pins 83 94 736 and fit the intake manifold.
Tightening torque: 22 Nm (16 lbf ft)
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16.
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Tighten the intake manifold steady bar bolts, beginning with the one in the cylinder block, and plug in the temperature sensor connector.
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17.
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Fit the bolts securing the water pipe to the thermostat housing cover and attach the throttle body preheating hose.
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18.
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Fit the lifting eyes and the bracket for the electrical connections.
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19.
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Connect the crankcase breather and vacuum hoses and fit the dipstick tube and bracket.
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20.
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Plug in the ignition discharge module connector and connect the water pipe for cooling the turbocharger.
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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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Fit the nuts for the front exhaust pipe or the turbocharger.
Tightening torque: 22 Nm (16 lbf ft).
Tighten the bolts securing the turbocharger steady bar, beginning with the one in the block.
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23.
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Fit the crankcase breather pipe and inlet pipe (turbo).
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24.
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Fit the servo pump and fit the pulley back in place. Fit the belt and check the position of all pulleys.
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25.
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Relieve the belt tensioner of strain, using a ratchet handle extension, and remove the drill.
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26.
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Fit the pressure pipe between the charge air cooler and the throttle body (turbo)
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27.
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Fit the inlet hose and by-pass hose (turbo).
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28.
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Fit the air cleaner. Fit the intake hose back in place and connect the mass air flow sensor (B206i B234i).
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29.
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Reconnect the negative battery cable, check that the radiator drain plug is tight, top up with coolant and check the system for leaks.
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30.
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Check the coolant and oil levels and top up as necessary.
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31.
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Fit the cover or the resonator, take the protective covers off the wings and make sure that the engine bay presents a neat and clean appearance.
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32.
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Start the engine, bleed the cooling system and check all functions. Drive the car on test.
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