PRE-RELEASE
Valve timing, checking
| Valve timing, checking |
(in car)
To remove| 1. |
Raise the car and remove the front right wheel.
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| 2. |
Remove the lower engine cover and drive belt cover.
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| 3. |
Mark up the multigroove belt rotation, relieve and remove the belt
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| 4. |
Remove the belt tensioner; storing it upright.
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| 5. |
Remove the front bolt on the torque arm and undo the rear one.
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| 6. |
Remove the crankshaft position sensor.
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| 7. |
Lower the car and remove the upper engine cover.
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| 8. |
Remove the intake manifold from the mass air flow sensor to the turbocharger and camshaft cover.
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| 9. |
Remove the charge air hose with charge air pipe from the turbo and the charge air pipe on the fan cowling. Plug the connections.
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| 10. |
Remove the turbocharger delivery pipe with hose from the throttle body and move it aside.
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| 11. |
Undo the cable rail and move it aside.
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| 12. |
Undo the vacuum hose to the brake servo and the vacuum hose connected to the bottom of the vacuum pump.
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| 13. |
Remove the four vacuum pump retaining bolts and carefully lift off the vacuum pump and its adapter. Be prepared with a rag or similar to collect any spilled oil.
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| 14. |
Undo the rear cable harness mounting on the camshaft cover.
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| 15. |
Remove the camshaft cover.
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| 16. |
Turn the crankshaft to just before the mark for top dead centre in cylinder 1. Make sure both cam lobes for cylinder 1 are pointing up.
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| 17. |
Insert
83 95 352 Setting tool, crankshaft
into the hole for the crankshaft position sensor. Push the tool somewhat inward at the same time as the crankshaft is turned to the zero point. The tool will then go into a recess in the crankshaft and lock it.
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| 18. |
Position
83 95 386 Adjustment tool, camshaft
on the camshaft and cylinder head. The valve timing must be adjusted if the gauge does not fit; see
Setting valve timing
.
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| 19. |
Remove the nut on the rear engine mounting.
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| 20. |
Remove the nut and the vibration damper on the right-hand engine mounting.
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| 21. |
Take the weight of the engine carefully with a jack and remove the upper right engine bracket.
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| 22. |
Dismantle the right-hand engine mounting.
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| 23. |
Raise the engine with the jack and remove the lower bracket.
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| 24. |
Lower the engine slightly and remove the bolts on the timing cover plate. Carefully insert a spatula behind the plate and prise it loose.
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| 25. |
Insert
83 95 337 Installation tool, fuel pump
in the fuel distribution pump recess. The valve timing must be adjusted if the gauge does not fit, see
Setting valve timing
.
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| 26. |
Remove the setting tool from the fuel distribution pump.
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| 27. |
Remove all setting tools.
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| 28. |
Cover the opening in the timing cover with a lint-free rag clean the sealing surface from any remnants of gasket. Clean the sealing surface on the cover plate as well.
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To fit
| 1. |
Apply a bead of
90 543 772 Silicon flange sealant
about 2mm thick on the cover plate, remove the rag from the timing cover and fit the cover plate.
Tightening torque: 6 Nm (5 lbf ft). 
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| 2. |
Fit the lower right engine bracket.
Tightening torque: 40 Nm + 90° (30 lbf ft + 90°) 
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| 3. |
Fit the right-hand engine mounting.
Tightening torque: 40 Nm + 30°(30 lbf ft + 30°) 
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| 4. |
Fit the upper bracket without tightening the bolts completely.
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| 5. |
Lower the jack until the upper bracket comes in contact with the engine mounting. Adjust the position of the upper bracket so that the engine mounting stud is situated as close as possible to the middle of the upper bracket hole.
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| 6. |
Fit the engine mounting vibration damper and nut and tighten the upper bracket retaining bolts.
Tightening torque: 40 Nm + 60° (30 lbf ft + 60°) |
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| 7. |
Lower the engine completely and remove the jack.
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| 8. |
Tighten the nut on the right-hand engine mounting.
Tightening torque: 105 Nm (77 lbf ft) |
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| 9. |
Fit the nut on the rear engine mounting.
Tightening torque: 47 Nm (35 lbf ft) 
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| 10. |
Clean the cylinder head sealing surfaces from any gasket remnants. Place a new gasket on the camshaft cover. The bolts where the gasket is fitted have sleeves. Apply
90 543 772 Silicon flange sealant
on the sealing surface, see illustration.
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| 11. |
Position the camshaft cover on the cylinder head and tighten the bolts.
Tightening torque: 8 Nm (6 lbf ft) |
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| 12. |
Fit the rear cable harness mounting on the camshaft cover.
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| 13. |
Clean the sealing surfaces on the vacuum pump and cylinder head. Place a new gasket on the vacuum pump, apply
90 543 772 Silicon flange sealant
as illustrated and fit the pump together with the adapter.
Tightening torque: 8 Nm (6 lbf ft) 
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| 14. |
Fit the cable rail and connect the vacuum hose to the vacuum pump.
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| 15. |
Fit the intake manifold from the mass air flow sensor to the turbo and the hose for the crankcase ventilation.
Tightening torque, mass air flow sensor: 3.5 Nm (2.5 lbf ft) 
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| 16. |
Raise the car and fit the crankshaft position sensor with a new O-ring.
Tightening torque: 8 Nm (6 lbf ft) 
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| 17. |
Fit the front torque arm bolt and tighten the rear one.
Tightening torque, front bolt 90 Nm + 90° (66 lbf ft + 90°) Tightening torque, rear bolt 50 Nm + 120° (37 lbf ft + 120°) |
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| 18. |
Fit the belt tensioner and tighten the upper bolt first.
Tightening torque: 42 Nm (31 lbf ft). 
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| 19. |
Tighten the lower bolt on the belt tensioner.
Tightening torque: 23 Nm (17 lbf ft). |
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| 20. |
Fit the multigroove belt, making sure it is positioned correctly over the belt pulleys and that the direction of rotation corresponds with the markings.
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| 21. |
Fit the drive belt cover and the lower engine cover.
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| 22. |
Fit the wheel
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| 23. |
Lower the car, connect the negative battery cable and fit the battery cover.
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| 24. |
Fit the upper engine cover.
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| 25. |
Adjust the clock, SID and calibrate ACC.
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