Front Cylinder Head

1. Make sure that the crankshaft is positioned at 60° BTDC.
2. Clean all contact surfaces and insert gasket. Note the guides for the gasket and that it is marked OPEN/TOP.
3. Install the exhaust manifold and the tappets to the cylinder head (if they have been removed).
4. Place the cylinder head in position. Use new bolts. Tighten in the order shown.
^ Stage 1: 25 Nm (18.5 ft. lbs.)
^ Stage 2: Tighten to 90°
^ Stage 3: Tighten to 90°
^ Stage 4: Tighten to 90°
5. Install the camshafts in place with gaskets. Lubricate generously with oil. Make sure that the locating pins are positioned as illustrated. Note the bearing cover markings and the markings in the cylinder head. Apply (10) 74 96 268, or equivalent sparingly to the front bearing cap contact surfaces with the cylinder head. Install the bearing caps and tighten the bolts to 8 Nm (6 ft. lbs.) in the order illustrated. Tighten in stages of 1/2 to 1 turn.





6. Install the two timing cover retaining screws in the cylinder head.
7. Check that the locating pins are in the correct position. If the locating pins are hollow, change them for solid pins.
8. Install the camshaft sprockets correctly in relation to the locating pins, as shown and tighten to 50 Nm (37 ft. lbs.) + 60°.

CAUTION: The open-ended wrench used as a holding tool when installing the camshaft sprockets must not have jaws that are too long. There is a danger of damaging the casting so that the tappet locks.





9. Install locking tool KM-800-1 on No. 1 and No. 2 camshaft sprockets and locking tool KM-800-2 on No. 3 and No. 4 camshaft sprockets.
10. Draw the crankshaft forward to just before 0° and install locking tool KM-800-10.to the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm is against the coolant pump flange and remove the tool.
11. Install the toothed belt in the marked direction of rotation. Use KM-800-30 to hold the belt in position, and lightly adjust the tensioner roller by hand so that the belt does not unmesh. Adjust counter clockwise. Install locking tool KM-800-10, install a piece of toothed belt and install tool 83 94 986, or equivalent to measure the belt tension. Lightly tighten the center bolts of the adjusting rollers. Adjust the lower adjusting roller counterclockwise to a belt tension of 275 - 300 Nm and tighten bolts to 40 Nm (30 ft. lbs.).

NOTE: The adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

12. Adjust the tensioning pulley with an allen wrench until the two marks are aligned. Tighten to 20 Nm (15 ft. lbs.). Remove the locking tool for camshaft sprockets 1 and 2. Then adjust the upper adjusting roller until camshaft sprocket No. 2 moves 1 - 2 mm clockwise and tighten to 40 Nm (30 ft. lbs.). Remove the upper locking tool.
13. Turn the engine two revolutions to just before the zero marking and install the locking tool to the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm is against the coolant pump flange and tighten it. Position tool KM-800-20 and check the markings on the camshaft sprocket are aligned with the markings on the tool and that the edge of the belt meets the edge of the sprocket.

NOTE: Also check the tensioning roller to ensure that the marks are in alignment.





14. Check that the O-rings are in place in the valve cover and wipe clean. Lubricate with soap water and apply (10) 81 52 381, or equivalent in the corners by the big-end bearing caps. Install the valve cover.
15. Install the timing cover.
16. Install the crankshaft pulley and tighten to 20 Nm (15 ft. lbs.).
17. Install the coolant pump pulley, the power steering servo pump, the belt tensioner and the multigroove belt.
18. Install the upper part of the generator air intake.
19. Install the torque arm engine mounting and install the servo line clamp.
20. Install the torque arm and bolt the lead onto the torque arm engine mounting.
21. Connect the upper hose to the expansion tank and install the power steering servo oil reservoir.





22. Install the lifting eye and install the secondary air injection pipe to the exhaust manifold. Install the heat shield.
23. Install the resonator bracket.
24. Install the ignition coil bracket and the ignition coil.
25. Install the spark plugs and tighten to 25 Nm (18.5 ft. lbs.) (if they have been removed) and connect the ignition leads.
26. Install the coolant bridge, using (10) 74 96 284, or equivalent on the bolts and tighten to 30 Nm (22 ft. lbs.).
27. Apply acid-free Vaseline to the lower intake manifold and install it. See illustration for order. Lock the bolts using (10) 74 96 268, or equivalent and tighten to 20 Nm (15 ft. lbs.).
28. Install the center intake manifold with fuel rail. Lock the bolts with (10) 74 96 268, or equivalent and tighten to 20 Nm (15 ft. lbs.).
29. Connect the fuel lines, the crankshaft position sensor and the injectors.





30. Place the intake manifold in position and connect the Traction Control System (TCS) throttle body.
31. Tighten the intake manifold bolts to 20 Nm (15 ft. lbs.).
32. Connect the crankcase ventilation hose to the intake manifold, reposition the wiring harness conduit under the throttle body and connect the throttle position sensor and the ignition coil.
33. Connect the vacuum hoses to the intake manifold and connect the throttle body preheater hoses.
34. Connect the Idle Air Control (IAC) valve and the hose to the fuel pressure regulator.





35. Align the inlet pipes with the resonator and connect the vacuum hoses and the wiring harness. Install the inlet pipes to the intake manifold and the resonator to the mass air flow sensor.
36. Install the throttle control bracket and fasten the control rod, the throttle cable and the cruise control cable. Adjust the kick-down cable and the throttle cable.
37. Install the engine covers and raise the car.





38. Check that the radiator drain plug is tightened and install the center air shield.
39. Bolt on the bracket for the check valves and fix the front exhaust pipe to the exhaust manifold. Lower the car.
40. Reconnect the negative cable to the battery. Remove the covers protecting the wings.
41. Top up with coolant and check the system for leaks.
42. Check other oil and fluid levels and top up if necessary. Check that the engine, engine bay and cabin are clean.

WARNING: The coolant is very hot and under high pressure. When the pressure cap is opened there is a danger of scalding. Take great care.

43. Bleed the cooling system as follows:
^ Fill the system up to the MAX level, install the pressure cap, start the engine and warm it up (preferably at different rpm) until the radiator fan starts.
^ Remove the pressure cap and refill to MAX.
^ Install the pressure cap and run the engine at varying rpm until the radiator fan starts three more times.
^ Switch off the engine and top up to the MAX level, if necessary.
44. Test drive the car and check all functions.