Assembly

NOTE: Use a suitable solvent to clean all flanges and mating surfaces thoroughly.





1. Lubricate pistons and rings before assembly.





^ Rotate the compression rings through 180° to bring the gaps in line with the boss for the wrist pin.





^ Rotate the scraper rings to ensure that the gaps are staggered.





2. Insert the pistons in their respective bores. Ensure that the arrow on the piston crown is pointing towards the timing end.





^ Install the piston using piston-ring clamp 78 62 287, or equivalent. Tap the pistons gently down inside the bores.





3. Place the bearing shells in their original positions and lubricate them.





4. Lift the crankshaft into position.





^ Adjust the positions of the bearing shells and install the two thrust washers for the main bearing between No. 2 and No. 3 cylinders, with the embossed side of the washers towards the main bearing.





5. Lubricate and install the main bearing caps on the respective bearings, making sure they are the right way round. Tighten the bearing caps to a torque of 20 Nm (15 ft. lbs.) and tighten a further quarter-turn (90°).





6. Lubricate and install the big-end caps in their respective positions, ensuring they are the right way round (number to number, and groove in shell to groove in shell). Tighten the bearing caps to a torque of 20 Nm (15 ft. lbs.) and tighten a further quarter-turn (90°).





7. Apply a bead of suitable anaerobic sealant, about 1 mm thick, along the flanges on the end plate. (Anaerobic sealant can harden without air being present.)





^ Install the end plate.





8. Install the flywheel.





9. Install the balance shaft
^ Rotate the crankshaft to bring the pistons in the No. 1 and No. 4 cylinders to TDC.
^ Carefully inspect the flange on the timing cover to ensure that it is absolutely clean.





^ Lubricate the balance-shaft journals and bearing housings.





^ Insert the balance shafts into their respective tunnels, taking great care not to damage the delicate bearings inside.

Balance Shaft Marks:

NOTE: The markings on the sprockets:
^ The shaft with the smaller thrust ring, marked INL, is the one for the inlet side of the engine.
^ The shaft with the larger thrust ring, marked EXH, is the one for the exhaust side of the engine.
^ Tighten the bearing housings to a torque 12 Nm (8.9 ft. lbs.).








10. Install the chain and sprocket on the crankshaft and install the chain guard.
11. Install the fixed chain guide that serves both the timing chain and the balance-shaft chain.





12. Install the pivoting guide for the timing chain.





13. Install the sprocket and oil-pump drive dog onto the crankshaft.





14. Install the balance-shaft chain and idler-wheel sprocket, ensuring that the timing marks on the bearing housing and sprocket are in line. On installation, leave some slack in the chain in line with the tensioner, and keep the chain reasonably taut by means of the top chain guide.








^ There is another way of installation the balance shaft chain:
Install the top chain guide first and then adjust the run of the chain round the sprockets. Adjusting the chain is easier this way, although it will be more awkward to install the idler-wheel sprocket.





15. Cock the chain tensioner and insert a paper clip or the like through the hole in the cylinder to prevent the tensioner being triggered. Before securing it, make sure that the plunger is turned to the position in which the spring acts fully on it.





^ Install the pivoting chain guide and the tensioner.





CAUTION: The tensioner must be correctly torqued to 12 Nm (8.9 ft. lbs.) to operate properly.





16. Install the top chain guide and trigger the tensioner. Rotate the crankshaft a few times to check that the chain is set up correctly.





17. See that the flanges on the timing cover are spotlessly clean and apply a bead of suitable anaerobic sealant, about 1 mm thick, along the middle of the flanges as shown.








^ Install the timing cover complete with oil pump, crankshaft sensor and reducing valve. Note that the bolts have three different lengths and install them as shown.





18. Make sure the flange on the sump is spotlessly clean and then apply Permatex Ultra Blue silicon sealant as shown.





^ Swivel the engine into a suitable position and install the sump.

Fig. 4 Cylinder Head Bolt Tightening Sequence:

19. Swivel the engine round again and install the cylinder head complete with a new gasket. Tighten the cylinder-head bolts in three stages in sequence shown:
a. 60 Nm (44 ft. lbs.)
b. 80 Nm (59 ft. lbs.)
c. A further quarter-turn (90°)





^ Remember the bolts installed through the timing cover from underneath.
20. Install the camshaft sprockets and chain, leaving the centre-bolts slack.





21. Install the chain tensioner. Note that a 27-mm socket is required.

Camshaft Marks:

22. Check that the chain is correctly seated in the guides. Rotate the crankshaft a few times and check that the timing is set correctly (flywheel and camshafts).





^ Torque the camshaft sprocket center-bolts to 60 Nm (44 ft. lbs.).





23. Clean the flanges on the camshaft cover and then apply a silicon sealant as shown.





^ Install the camshaft cover.





24. Install the ignition module (cartridge) and connect the earth lead from the loom together with the clip to the fuel-pressure regulator bracket.








25. Install the locking segment 83 93 987, or equivalent followed by the crankshaft pulley and tighten to 190 Nm (140 ft. lbs.). Remove the locking segment.





26. Lubricate the O-ring with Vaseline and install the water pump.





27. Install the front engine mounting.





28. Lubricate the O-ring with Vaseline and connect the pipe between the :water pump and the heater-box hoses. Install the clip for the crankshaft-sensor lead and tie the lead to the pipe.





29. Install the steering servo pump complete with bracket and idler-wheel pulley.





30. Install the top engine mounting.





31. Install the alternator.





32. Install the adaptor and oil filter.





33. Install the inlet manifold (with new gasket) complete with engine wiring loom and:
^ Connect the leads to the alternator
^ Connect the fuel hose to the fuel-pressure regulator
^ Connect the hoses to the throttle housing
^ Connect the crankcase breather hoses to the camshaft cover
^ Install the bracket for the dipstick tube.





34. Install the belt tensioner.





35. Using new gaskets, install the exhaust manifold: outer section first and inner section last.





36. Install the bracket for the AC compressor.





37. Check that the torque converter is properly seated inside the gearbox and that tool 87 91 816, or equivalent is installed. Lift the gearbox into position and tighten the securing bolts.





38. Install the securing bolts for the flywheel (through the aperture in the back-plate).
39. Remove the lifting beam 87 91 451, or equivalent and install the gearbox breather valve.





40. Connect the kickdown cable to the throttle linkage and install the clip securing the cable to the bracket.





41. Install a lifting sling to the engine and lift the engine off the stand. Remove the bracket and lower the engine onto a trolley.





42. Install the engine mounting/support bearing bracket complete with the tube and inner drive-shaft joint.
43. Install the starter motor and reconnect the leads. The engine is now ready for installation in the car.