Assembly

CAUTION: The bearing shells for main bearing caps 2 and 3 have no oil hole. Be careful with the classification of bearing shells for block and bearing caps. Wash all sealing surfaces with washing gasoline so that they are completely clean.





1. Place all main bearings in their places and oil them.

NOTE: The aperture disc must be handled with great care. Make sure that the main bearing member adjusting sleeves are screwed tight, if they are not locked.

2. Install the perforated disc, the bolts should be locked with (10) 74 96 268, or equivalent and place the crankshaft in position.
3. Lubricate and install all main bearing caps in their original positions, making sure they are the right way around. Install the main bearing member and tighten the main bearing cap bolts. See illustration for order. Torque bolts to 50 Nm (37 ft. lbs.) + 60° + 15°.
4. Screw down the adjusting sleeves flush. Place (10) 74 96 268, or equivalent on the outer bolts of the main bearing and tighten to 20 Nm (15 ft. lbs.).
5. Spray (10) 81 52 381, or equivalent in the splicing joints at the rear main bearing. Do not stop until the compound is forced out at the side.





6. Turn the engine and angle it so that cylinders 1-3-5 are vertical. Oil the pistons and rings, adjust the position of the ring gaps as illustrated and install the pistons in their cylinders.
I. The front marking on the top of the piston towards the timing end.
1. Upper compression ring
2. Lower compression ring
3. Steel spacer ring (top oil-scraper ring)
4. Middle ring (oil-scraper ring)
5. Steel spacer ring (bottom oil-scraper ring)

The arrow markings on the top of the pistons should point to the transmission side of the engine. Use installing sleeve 83 95 113, or equivalent and carefully tap the pistons into the cylinder bores. Do the same with cylinders 2-4-6.
7. Lubricate and install all connecting rod bearing caps in their original positions and make sure they are the right way around (the rib should be facing the gearbox side). Blow the contact surfaces clean. If they are damaged, the connecting rod must be changed. Torque bolts to 35 Nm (26 ft. lbs.) + 45° + 15°.





8. Install a new crankshaft gasket using tools 83 94 967 and 83 94 975, or equivalents and install the flywheel or the drive plate. Apply (10) 74 96 292, or equivalent to the bolts and tighten to 65 Nm (48 ft. lbs.) + 30°.
9. Install the oil pump complete with a new gasket. Apply (10) 93 21 795, or equivalent to the gaskets. Torque bolts to 6 Nm (4.5 ft. lbs.).
10. Install the bottom adjusting roller and tighten to 40 Nm (30 ft. lbs.).
11. Install a new crankshaft seal using tool 83 94 942, or equivalent.
12. Install holder 83 95 063, or equivalent. Install the oil pressure sensor. Apply (10) 93 21 795, or equivalent to the reverse of the toothed belt sprocket and tighten to 250 Nm (184.5 ft. lbs.) + 45°.





13. Turn the engine and apply (10) 81 52 381, or equivalent in the partition joints, see illustration.
14. Install the oil antislosh baffles. Lock the bolts with (10) 74 96 268, or equivalent. Torque bolts 8 Nm (6 ft. lbs.).
15. Install the oil vacuum pipe complete with oil ring. Lock the bolts with (10) 74 96 268, or equivalent. Torque pipe to 8 Nm (6 ft. lbs.).
16. Install the oil pan complete with new gasket. See illustration for order. Lock the bolts with (10) 74 96 268, or equivalent. Torque bolts to 15 Nm (11 ft. lbs.).





17. Turn the engine, clean the heat exchanger lid with washing gasoline and apply (10) 81 52 381, or equivalent in the groove. Install the heat exchanger using a new gasket.
18. Tighten the cover to 20 Nm (15 ft. lbs.).
19. Connect the oil pipe to the heat exchanger complete with new gasket and tighten the connectors to 30 Nm (22 ft. lbs.).
20. Install new cylinder head gaskets. Be careful of the oil ducts (see illustration). For cylinders 1,3,5 the marking "OPEN/TOP" should face the gearbox end. For cylinders 2,4,6 the marking should face the timing end of the engine.





21. Turn the crankshaft to approximately 60° BTDC and install the cylinder heads using new bolts in sequence, see illustration. Torque to 25 Nm (18.5 ft. lbs.) + 90° + 90° + 90°.
22. Remove the protective sleeves and install the valve depressors.
23. Position the camshafts and install the caps. Start where the tappets point down and are pressing on the depressors. Coat lightly with (10) 74 96 268, or equivalent on the contact surfaces between the front bearing caps and the cylinder heads. Torque bolts to 8 Nm (6 ft. lbs.).

Cylinders 1-3-5
The guide pin on the camshaft should point towards the internal bolts for the camshaft bearing caps, see illustration.

Cylinders 2-4-6
The locating pin for the intake camshaft should be in line (downwards) with the internal bolt for the camshaft bearing cap, see illustration. The locating pin for the exhaust camshaft should be in line with the edge of the camshaft sensor (upwards), see illustration.

NOTE: Tighten the bolts gradually-1/2 to 1 turn. The markings on the camshaft bearing caps and the cylinder head must match. The caps marked L1 - L8 are for the cylinder head for cylinders 1,3,5 and R1 - R8 are for cylinders 2,4,6. The camshaft bearing seats in each cylinder head are numbered 1-8.

24. Install the camshaft position sensor and the rear timing cover.





25. Coat the new O-ring for the coolant pump and the sealing surface on the cylinder block with acid-free Vaseline. Install the coolant pump and tighten to 25 Nm (18.5 ft. lbs.).
26. Install the bracket with the tensioning pulley and the upper adjusting roller and tighten to 40 Nm (30 ft. lbs.).
27. Lubricate and install the new camshaft gasket with tool 83 94 959, or equivalent and install the camshaft sprockets.

CAUTION: The open-ended wrench that is 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 valve tappet seizes. The sprocket should be installed so at the number in the hub of the sprocket matches the camshaft order number. Torque to 50 Nm (37 ft. lbs.) + 60°.

28. Carefully turn the camshafts so that the markings on the camshaft sprockets are aligned with the grooves on the rear of the timing cover, use KM-800-20. Lock the camshafts using KM-800-1 (cylinders 1-3-5) and KM-800-2 (cylinders 2-4-6).
29. Turn the crankshaft in the direction of rotation of the engine to BTDC. Install KM-800-10 to the crankshaft and turn the shaft to TDC. Push the moveable arm against the flat part of the coolant pump flange and attach it.





30. Install a new toothed belt with the arrows aligned in the direction of engine rotation. Start with the double line marking by the line marking on the toothed belt sprocket on the crankshaft. Use KM-800-30 to hold the belt in place.
31. Install the toothed belt over the bottom adjusting roller and then over camshaft sprockets 3 and 4. The line markings on the belt should match with the grooves on the camshaft sprockets and the rear timing cover. The adjusting roller may have to be loosened before the toothed belt can be installed.
32. Insert the toothed belt under the top adjusting roller, and then place the belt on camshaft sprockets 1 and 2. The line markings on the belt should match the grooves on the camshaft sprockets and the rear timing cover. The adjusting roller may need to be loosened before the toothed belt can be installed.
33. Place the toothed belt over the tensioning pulley. Set the valve timing.





34. Install the timing cover.
35. Install the coolant pump pulley and tighten to 8 Nm (6 ft. lbs.).
36. Tighten the crankshaft pulley to 20 Nm (15 ft. lbs.).





37. Install new gaskets to the valve covers and wipe clean. Lubricate with soapy water and apply (10) 81 52 381, or equivalent in the corners by the camshaft bearing caps. Install the valve covers.
38. Install the spark plugs and tighten to 25 Nm (18.5 ft. lbs.).
39. Install the crankcase ventilation housing using two of the bolts.
40. Install the coolant bridge complete with new copper gaskets. Apply (10) 74 96 284, or equivalent to the bolts and tighten to 30 Nm (22 ft. lbs.).
41. Install the thermostat with a new O-ring. Dampen the O-ring with coolant. Tighten to 20 Nm (15 ft. lbs.).
42. Install the coolant pipe complete with new O-rings. Installing is easier if the O-rings have been dampened with coolant. Tighten to 20 Nm (15 ft. lbs.).
43. Install the lower intake manifold complete with new gaskets. Tighten the bolts to 20 Nm (15 ft. lbs.) and lock them using (10) 74 96 268, or equivalent.
44. Install the center intake manifold to the fuel pressure regulator by the timing cover. Lock the bolts using (10) 74 96 268, or equivalent and tighten to 20 Nm (15 ft. lbs.).





45. Install the oil filter and tighten to 10 Nm (7.4 ft. lbs.).
46. Connect the oil lines to the cylinder block. Tighten to 30 Nm (22 ft. lbs.).
47. Install the bracket for the ignition coil and the accelerator linkage and install the ignition coil complete with ignition leads.
48. Clean the surface under the knock sensors and install the knock sensors. Tighten to 22 Nm (16 ft. lbs.).
49. Install the crankshaft position sensor using a new O-ring. Tighten to 8 Nm (6 ft. lbs.).
50. Install new gaskets and install the exhaust manifolds. Use new nuts and tighten to 20 Nm (15 ft. lbs.).
51. Install the dipstick level tube.





52. Install the intake manifold with wiring harness.
53. Connect the rear knock sensor, the engine oil pressure sensor, the injector leads and the camshaft position sensor.
54. Bolt the grounding leads to the bracket and connect the ignition coil and the temperature sensors.
55. Connect the throttle body preheater hose.
56. Connect the crankcase ventilation hose to the intake manifold.





57. Install the generator and connect it. Clip in the lead for the oil pressure sensor.
58. Install the belt tensioner tighten bolt to 40 Nm (30 ft. lbs.).
59. Fix the right-hand engine mounting bracket.
60. Place the multi-groove belt in position and install the torque arm engine mounting.





61. Hook on a lifting yoke and raise the engine from the stand. Remove the holder.
62. Install the coolant intake and the secondary air injection pipes. Attach the fixing between the oil lines.
63. Install the heat shield over the front exhaust manifold.





64. Position and tighten the gearbox. Tighten bolts to 75 Nm (55 ft. lbs.).
65. Connect the speedometer sensor.
66. Remove the torque converter fixing tool and install the cover plate and tighten bolts to 7 Nm (5 ft. lbs.) (automatic transmission).
67. Connect the drive plate and the torque converter by slowly rotating the crankshaft so that all bolts can be tightened to 60 Nm (44 ft. lbs.) (automatic transmission).
68. Install the plastic plugs under the starter motor.
69. Install the starter motor, connect the leads and install the wiring harness bracket on the crankcase ventilation housing.
70. Install the support bearing bracket complete with tube and internal universal joint. The power train is now ready to be installed in the car.