To fit

Carefully blow the bolt hole clean in the cylinder block with compressed air.
Clean the cylinder bore, cylinder head and cylinder block sealing surfaces from any gasket remains. Check with a steel rule that the cylinder head and cylinder block are flat and the sealing surfaces are not damaged.
Check the marks on the pulley and timing cover to make sure the engine is zeroed.
Place a new gasket on the cylinder block. Raise the sprocket and tighten the chain guides together in order to get the cylinder head in place.

Fig 1: Illustration For Steps 4
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Remove the exhaust camshaft and intake camshaft bearing cap no. 2. Fit 83 96 046 CAMSHAFT SETTING TOOL KIT or 83 96 079 CAMSHAFT SETTING TOOL (B207 200 HP) onto the camshafts.
Tightening torque 10 Nm (7 lbf ft)

Fig 2: Illustration For Steps 5
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Fit the cylinder head according to the order shown in the illustration. Insert the bolts carefully. The threads in the cylinder block can be damaged if they are dropped rapidly.
Tightening torque step 1: 30 Nm (22 lbf ft)

Tightening torque step 2: 75°

Tightening torque step 3: 80°

Tightening torque, bolts for timing section, 25 Nm (18 lbf ft)

Fig 3: Illustration For Steps 1-10
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Remove the bolt for the chain guide. Move back the guide and fit the bolt.
Tightening torque 10 Nm (7 lbf ft)

Fig 4: Illustration For Step 7, 8, 10, 11
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Fit the plug in the cylinder head.
Tightening torque 25 Nm (18 lbf ft)
Fit the sprocket on the exhaust camshaft and intake camshaft without tightening. Check that the engine is zeroed.
Fit the chain guide "zeroed". The groove on the end of the chain tensioner must be vertical when fitting. See TIMING CHAIN TENSIONER - fitting. Use 83 96 129 OIL FILTER TOOL B207, AND CHAIN TENSIONER CAMSHAFT DRIVE
NOTE: Check that chain tensioner O-ring and gasket are intact. If damaged, the entire chain tensioner must be changed.

Tightening torque 75 Nm (55 lbf ft)
Tighten the camshaft sprockets. Grip the respective camshaft on its flats. Remove the cable tie.
Tightening torque 85 Nm + 30° (63 lbf ft +30°)
Remove the camshaft adjustment tool and fit the camshaft caps.
Tightening torque 8 Nm (6 lbf ft)
Turn over the engine 2 revolutions and zero so that the belt pulley and the timing cover marks agree. Remove bearing caps no. 2 and no. 7 and fit 83 96 046 CAMSHAFT SETTING TOOL 175 HP or 83 96 079 CAMSHAFT SETTING TOOL (B207 200 HP) again to check that the camshaft setting is correct. Remove the setting tools and fit the bearing caps.

Fig 5: Illustration For Step 13
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Fit the screw for the dipstick. Plug in the connector and fit the connector to the tube.

Fig 6: Illustration For Steps 15-17
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Cars with secondary air injection pump : Fit the pump's top retaining bolt. Fit the pipe between the pump and the valve.
Fit the power steering pump with new seal.
Tightening torque 22 Nm (16 lbf ft)

Fig 7: Illustration For Steps 21, 22
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Connect coolant hose to pipe on cylinder head. Attach vacuum hose to brake servo.
Fit the right-hand engine pad.
Tightening torque, bolts to body 40 Nm + 60° (30 lbf ft + 60 °)

Tightening torque, bolts to bracket 70 Nm + 60° (52 lbf ft + 60 °)

Fig 8: Illustration For Steps 23, 24
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Fit coolant hose to pipe on cylinder head.
Fit the camshaft cover with new seal.
Tightening torque 10 Nm (7 lbf ft)

Fig 9: Illustration For Steps 25
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Connect the ground cable to the camshaft cover.

Fig 10: Illustration For Step 25
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Connect the crankcase ventilation hose to the camshaft cover.
Fit the ignition coils.
Tightening torque 8 Nm (6 lbf ft)
Fit the wiring harness to the intake manifold and oil filter housing.

Fig 11: Illustration For Step 29
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Fit the cable duct and bracket to the camshaft cover.

Fig 12: Illustration For Step 30-32
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Connect hose to turbocharger wastegate and solenoid valve.
Plug in A/C pressure sensor connector, connector to coolant temperature sensor, engine control module, bypass valve solenoid valve, throttle body, intake manifold pressure sensor, atmospheric pressure sensor, IDM module, oil pressure sensor and ground cable on engine control module.
Plug in the ignition coil connectors. Make sure the cable is lying correctly and does not get pinched by the cover. Plug connector to turbocharger solenoid valve and cable clips.

Fig 13: Illustration For Steps 33
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Fit cover over ignition coils.

Fig 14: Illustration For Steps 34
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Press the fuel lines and breather lines into the clips on the camshaft cover. Connect the quick release coupling for the breather line.

Fig 15: Illustration For Steps 30, 31
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Connect both fuel lines to the fuel rail while gripping the lower nut. Use new seals.
Tightening torque 10 Nm (7 lbf ft)
Fit the air cleaner casing and connect the intake hose. Fit the air cleaner.

Fig 16: Illustration For Step 37
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IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
Connect air filter housing cover. Plug in the mass air flow sensor connector and fit the turbo inlet pipe. Attach hoses to turbo inlet pipe.

Fig 17: Illustration For Steps 33
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Fit the turbocharger delivery hose to the throttle body and the turbo delivery pipe.

Fig 18: Illustration For Step 39
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Connect the starter motor positive cable.

Fig 19: Illustration For Step 43, 44
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Fit the stay between the intake manifold and the cylinder block.
Tightening torque 22 Nm (16 lbf ft)
Fit the oil return pipe to the turbo. Use a new gasket and new O-ring.
Tightening torque 15 Nm (11 lbf ft)

Fig 20: Illustration For Steps 45-47
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Fit the stay between the exhaust manifold and the cylinder block.
Tightening torque 22 Nm (16 lbf ft)
Fit the turbo coolant pipe with new seals.
Tightening torque 40 Nm (30 lbf ft) .
Lower the car and fit the catalytic converter with new nuts so that it is butt against the turbo. Use 30 20 971 Screw-thread paste on the studs.
Tightening torque 25 Nm (18 lbf ft)

Fig 21: Illustration For Step 40, 41
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Raise the car and tighten the catalytic converter bracket bolts.
Tightening torque 25 Nm (18 lbf ft)
Fit the lower turbocharger pressure pipe.

Fig 22: Illustration For Step 58
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Fit the lower spoiler shield. CV: Fit the front subframe chassis reinforcement.

Fig 23: Illustration For Step 59
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Lower the car somewhat and fit the right wing liner and the front right wheel. See WHEEL .

Fig 24: Illustration For Steps 60
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Fit the turbo oil pressure pipe. Use new seals and grip the pipe to prevent it twisting.
Tightening torque 22 Nm (16 lbf ft)

Fig 25: Illustration For Steps 61, 62
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Plug in the oxygen sensor connectors.

Fig 26: Illustration For Steps 46, 47
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Fit the heat shield over the turbocharger.
Connect battery negative cable and battery cover.

Fig 27: Illustration For Steps 65, 69
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Check the oil level and top up as necessary.
Fill with coolant to approx. 20 mm above the mark on the expansion tank.

Fig 28: Identifying Coolant Tank
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Remove the wing covers and restore car electrical functions, see AFTER DISCONNECTING THE BATTERY .
Fit the upper engine cover.