Installation

1. Position the impellers in the housing and install the lid. Lock the bolts with (10) 74 96 268, or equivalent and tighten to 6 Nm (4.5 ft. lbs.).

NOTE: The marks on the impellers should be on the outside when installing.

2. Position a new gasket, coat with (10) 93 21 795, or equivalent and install the pump housing and tighten bolts to 6 Nm (4.5 ft. lbs.).





3. Install the A/C compressor bracket.
4. Raise the car and remove the stand.
5. Install the cable for the oil pressure switch.
6. Seal the joints in the partition surface using (10) 81 52 381, or equivalent.
7. Install the oil strainer and the oil pan. Lock the bolts using (10) 74 96 268, or equivalent. Torque bolts for the oil strainer to 8 Nm (6 ft. lbs.) and the oil pan to 15 Nm (11 ft. lbs.).
8. Install the A/C compressor.
9. Install the alternator.





10. Use holder 83 95 063, or equivalent and install the crankshaft sprocket and tighten mounting bolt to 250 Nm (184.5 ft. lbs.) + 45°.
11. Remove the holder and install the cover plate.
12. Install the front exhaust pipe.
13. Check that the radiator drain plug is installed properly. Install the center air shield and lower the car.
14. Install the rear timing cover and tighten the bolts.
15. Check that the camshafts are in the correct position. If the locating pins are hollow, change them for solid pins.
16. Install the camshaft sprockets and check the position against the markings in the timing cover. Lock the camshaft sprockets with locking tools KM-800-1 and KM-800-2 and tighten the bolts to 50 Nm (37 ft. lbs.) + 60°.
17. Install the bracket for the tensioning roller and the upper adjusting roller.





18. 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.
19. Turn the crankshaft to just before 0° and install locking tool KM-800-10 on the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm is against the coolant pump flange and tighten it.
20. Install the toothed belt according to its marked direction of rotation. Use KM-800-30 to hold the belt in place. Adjust the tensioning roller loosely by hand to prevent the belt from slipping out of the cogs. Adjust counter-clockwise. Install a length of the toothed belt in place and install tool 83 93 985, 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. Torque mounting bolt 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 ten the belt is finally adjusted.

21. 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. Adjust the upper adjusting roller counter-clockwise until the No. 2 sprocket moves 1 - 2 mm clockwise then tighten to 40 Nm (30 ft. lbs.). Remove the upper locking tool.
22. 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.





23. Install the crankshaft pulley and tighten to 20 Nm (15 ft. lbs.).
24. Install the timing cover.
25. Install the power steering servo pump.
26. Install the belt tensioner. Torque mounting bolt to 40 Nm (30 ft. lbs.).
27. Install the upper part of the generator air intake.
28. Install the coolant pump pulley and connect the upper hose to the expansion tank.
29. Release the load from the belt tensioner by turning the belt tensioner pulley forwards in the car using a 15 mm wrench. Install the belt on the coolant pump pulley and check the position on the other pulleys. Carefully release the belt tensioner.
30. Install the torque arm engine mounting and install the servo line clamp.
31. Install the torque arm, bolt the lead to the torque arm engine mounting and hook on the power steering servo oil reservoir.
32. Connect the negative lead to the battery. Change the oil filter and top up the engine oil. Top up the coolant and check there are no leaks.
33. Check other oil and fluid levels and top up if necessary. Check the engine compartment is clean. Remove the fender covers.

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.

34. Bleed the cooling system as follows:
^ Fill the system to the MAX level and install the pressure cap. Start the engine and nun it until it is warm, preferably at varying rpm, and the radiator fan starts. Remove the pressure cap and refill to MAX.
^ Install the pressure cap and let the engine run at varying rpm until the radiator fan has started three more times.
^ Switch off the engine and top up to the MAX level if necessary.
35. Test drive the car and check all functions.