To assemble the engine

Wash all sealing surfaces with benzine, making sure that they are perfectly clean.

Fig 1: Illustration For Steps 1-3

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1. Fit the piston cooling nozzles. Place all main bearings in their correct positions and coat them with oil.

   Tightening torque: 18 Nm (13 lbf ft)  .

   IMPORTANT: Observe the utmost care when handling the slotted ring.
2. Fit the slotted ring, place the crankshaft in position and fit the two thrust washers at the main bearing between the No. 2 and No. 3 cylinders. Fit the washers with the embossed side facing towards the main bearing so that the bearing surface is the right way round.
3. Lubricate and fit all main bearing caps in their correct places, making sure that they are the right way round.

   Tightening torque 20 Nm + 70 (15 lbf ft + 70)  .

4. Turn the compression rings so that the gaps in the rings are moved 180 and located directly opposite the gudgeon pin ends. Also make sure that the upper and lower spring gap on the three-piece oil scraper ring are not lined up opposite each other.
   Fig 2: Illustration For Steps 4-5

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5. Fit PROTECTIVE COLLARS  75 19 531 to the crankshaft studs, oil the pistons and rings, then fit the pistons in their respective cylinders. The arrow markings on the piston crowns should be turned towards the engine's timing chain end. Use PISTON FITTING TOOL  78 62 287 and carefully tap down the pistons in the bores.
6. Lubricate and fit all big-end bearing caps in their original positions, making sure that they are the right way round (number to number, groove in shell to groove in shell).

   Tightening torque with nut 20 Nm + 70 (15 lbf ft + 70) 

   Tightening torque with bolt 25 Nm + 100 (18 lbf ft + 100) 

7. Apply a bead of Loctite 518 about 1 mm thick on the end plate's mating surface and fit the plate in place. Mind the seal.
   Fig 3: Illustration For Steps 7, 9 & 10

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8. Align the crankshaft with the wedge straight up (corresponding to the 0 mark on the crankshaft pulley).
9. Fit the flywheel or the driven plate, using Loctite 270D on the bolts.
10. Fit FLYWHEEL LOCKING ATTACHMENT  83 94 868 and tighten the bolts.

    Tightening torque, flywheel and drive plate 20 Nm +50° (15 lbf ft +50°) 

11. Lubricate the bearing surfaces on the balancer shafts and in the bearing housings and insert the balancer shafts into their respective tunnels, taking the utmost care to avoid damaging the bearing shells inside.
    Fig 4: Illustration For Steps 11-14

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    IMPORTANT: The shaft with the smaller thrust ring marked INL should be mounted on the inlet side and the shaft with the larger thrust ring marked EXH should be mounted on the exhaust side.
12. Check the timing chain and fit the sprocket and chain onto the crankshaft end, marking to marking, and bolt the safety plate in place.
13. First fit the fixed chain guide, which is common to the timing chain and balancer-shaft chain, and then the pivoted chain guides for the timing and balancer-shaft chains.
14. Fit the balancer-shaft sprocket and the oil-pump driver onto the crankshaft end.
15. Cock the chain tensioner and insert a paper clip or similar object through the hole in the cylinder to prevent triggering of the tensioner. Before this, check that the plunger is turned to the position where it really is pressed out by the spring.
    Fig 5: Illustration For Steps 15-16

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16. Fit the chain tensioner.

    Tightening torque: 10 Nm (7 lbf ft)  .

    WARNING: It is extremely important for the function that the correct torque is applied when fitting.
17. Inspect the balancer-shaft chain and fit it and the idler sprocket so that the upper setting marks behind the balancer-shaft sprocket and bearing housing are in line with each other. Tauten the chain between the crankshaft and balancer shafts. Fit the idler sprocket last. Hold the bolt in place with your thumb, mesh the teeth of the sprocket with the chain and roll it along the chain into position.
    Fig 6: Illustration For Steps 17-19

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18. Check the marking on the balancer-shaft sprocket and remove the flywheel locking segment.
19. Setting: Fit the timing cover using two bolts only and do not tighten them. Mount the crankshaft pulley. Rotate the pulley one revolution. Reset the crankshaft relative to the timing cover. Remove the timing cover and crankshaft pulley carefully, making sure that the crankshaft does not move, and check the settings of the balancer shafts.
20. Check that the timing cover joint face is perfectly clean. Apply Loctite 518 in an approx. 1 mm bead on the timing cover. Apply the bead in the middle of the mating faces.
    Fig 7: Illustration For Step 21

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21. Fit the timing cover.

    Tightening torque 22 Nm (16 lbf ft)  .

22. Fit the oil pump, flywheel locking segment and crankshaft pulley. Remove the flywheel locking segment.

    Tightening torque 175 Nm (130 lbf ft)  .

23. Fit the oil pump pressure pipe and check that there are no impurities or other foreign matter in the oil sump.
    Fig 8: Illustration For Steps 23-25

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24. Fit the adapter housing and oil filter.
25. Check that the mating surface of the oil sump is perfectly clean and apply an even coating of Loctite 518 along it. Turn the engine to a suitable position and fit the oil sump.

    Tightening torque 22 Nm (16 lbf ft)  .

26. Carefully clean all sealing surfaces. Apply a 2 mm thick and 10-20 mm long bead of Loctite 518, part No. 93 21 795, to the inner part of the upper contact surface of the timing cover (against the cylinder head). Turn the engine in the stand, turning the crankshaft 45° to lower the pistons.

    Fit a rubber band round the chain guides  and fit the cylinder head using a new gasket. Check that it is correctly seated on the locating sleeves and that the chain runs freely.

    Fig 9: Illustration For Step 26

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    Tighten the cylinder head bolts in three stages  :

    1. Step I: 40 Nm (30 lbf ft) 
    2. Step II: 60 Nm (44 lbf ft) 
    3. Step III: Tighten a further 90 

    Tighten the bolts in the order shown in the illustration  .

27. Fit the two screws between the timing cover and the cylinder head.
    Fig 10: Illustration For Steps 27-29

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    Tightening torque 22 Nm (16 lbf ft)  .

28. Remove the rubber band and check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the 0 mark.
29. Fit the camshaft sprockets and chain. Start with the camshaft on the exhaust side.

    The marking on the sprockets should be in the center of the chain markings (only when the engine is fully zeroed, i.e. crankshaft aligned with the 0 mark). Do not tighten the bolts yet.

30. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
    Fig 11: Illustration For Steps 30-32

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31. Fit the chain tensioner, using a 27 mm socket.

    Tightening torque 63 Nm (47 lbf ft)  .

32. Fit the chain tensioner plug with push rod and spring.

    Tightening torque 22 Nm (16 lbf ft)  .

33. Check that the chain is correctly seated in the guides. Rotate the crankshaft two complete turns and check the settings of the crankshaft pulley and camshafts.
34. Tighten the camshaft sprocket bolts.

    Tightening torque 63 Nm (47 lbf ft)  .

35. Fit the spark plugs.
    Fig 12: Illustration For Steps 35, 37 & 38

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    Tightening torque 28 Nm (21 lbf ft)  .

36. Clean the sealing surface of the camshaft cover with benzine.
37. Apply oil to the camshaft cover's opening and fit the cover, starting at the opening. Then tighten the bolt located furthest to the front at the timing chain end. After that, continue all the way round on both the inside and outside.

    Tightening torque 15 Nm (11 lbf ft)  .

38. Fit the ignition discharge module.

    Tightening torque 11 Nm (8 lbf ft)  .

39. Fit the crankshaft position sensor.
    Fig 13: Illustration For Steps 39-40

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40. Check the coolant pump O-rings, and replace them if necessary.

    Clean the hole in the block and tighten the sleeve, using a torque wrench, with its large wing pointing horizontally towards the flywheel end.

    Grease the O-rings with acid-free petroleum jelly and fit the coolant pump and coolant pipes from the expansion tank and heat exchanger. Fit the clips for the crankshaft position sensor cable at the same time.

41. Fit a new gasket for the exhaust manifold.
42. Fit the turbocharger with exhaust manifold and steady bar.
    Fig 14: Illustration For Steps 42-47

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    Tightening torque 25 Nm (19 lbf ft)  .

43. Fit the crankcase breather pipe together with the intake manifold. Mind the O-ring.
44. Connect the coolant and oil pipes.
    IMPORTANT: The rubber seals should be placed against the adapter housing, or water pump and cylinder head.
45. Fit the power steering pump with bracket and fit the turbo wastegate.
46. Fit the A/C compressor bracket.
47. Fit the heat shield over the turbocharger.
48. Clean all gasket surfaces between the intake manifold and cylinder head.
    Fig 15: Illustration For Steps 49-50

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49. Align the intake manifold gasket with the aid of the outer retaining bolts and fit the intake manifold.

    Tightening torque 22 Nm (16 lbf ft)  .

50. Reconnect the hoses from the throttle body.
51. Plug in all electric connectors between the intake manifold and the remainder of the power train and fit its bracket in the lifting lug.
52. Fit the pressure pipe between the throttle body and charge air cooler.
    Fig 16: Illustration For Step 52

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53. Connect the crankcase breather pipe to the turbocharger's inlet pipe and plug in the wiring.
54. Fit the oil filler pipe with bracket.
    Fig 17: Illustration For Steps 54, 55, 57 & 59

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55. Check that the torque converter bottoms in the transmission casing and that the locking screw is fitted (aut.). Fit the automatic transmission in place and tighten the bolts.
56. Fit the torque converter bolts (aut.). Apply Loctite 270D to the threads.

    Turning torque 60 Nm (44 lbf ft)  .

57. Fit the flywheel cover.
58. Fit a lifting sling to the engine and lift it off the stand.
59. Remove the holder and fit the rear engine mounting bracket and gearbox retaining bolt.
60. Position the engine on the subframe and fit the rear engine mounting, tightening it with a torque wrench.
    Fig 18: Illustration For Step 60

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    Tightening torque 50 Nm (37 lbf ft)  .

61. Fit the front exhaust pipe with sensor. Fit the gearbox steady bar and tighten it, using a torque wrench.
    Fig 19: Illustration For Step 61

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62. Fit the bearing bracket with intermediate shaft and inboard drive-shaft joint.
63. Fit the oil trap and connect its hoses.
    Fig 20: Illustration For Steps 63-65

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64. Fit the intake manifold steady bar.
65. Fit and connect the generator, starter motor and belt tensioner.
66. Check that the oil plug is properly tightened. The power train is now ready for fitting in the car.

    Tightening torque 25 Nm (19 lbf ft)  .