Installation

NOTE: The method described applies to a car equipped with water-cooled turbo, intercooler, AC, automatic transmission, catalytic converter, two-stage cooling fan and automatic belt tensioner. The procedure will obviously need to be adapted as appropriate to suit cars to different specifications.

1. Inspect all gaskets to ensure that all traces of gasket and sealant have been removed. If necessary, clean the flanges with using industrial petrol (benzine).





2. Apply a bead of Permatex Ultra Blue sealant (45-30 20 856) along the groove on the sump. Fit new gaskets to the flanges on the block.








3. Fit the timing cover making sure that the oil pipe is inserted through the hole in the cover (see dimension shown). Do not fit the bolts for the pump and oil-cooler pipes yet. Reconnect the coolant pipe complete with '0' ring to the water pump. Tightening torque for timing cover: 20 Nm (15 ft lb).

NOTE: The bolts securing the cover to the cylinder head must not be tightened until after the oil pump has been fitted.

4. After inspecting the seal, fit the oil pump.

Length Of Bolts For Timing Cover And Sump In Millimeters:

NOTE: Before tightening bolts, ensure that oil pipe is correctly positioned through hole in cover.

5. Tighten the oil-pump securing bolts to the torque 8 Nm (6 ft lb) and the two through-bolts through the pump and timing cover to the torque 20 Nm (15 ft lb).





6. After inspecting the '0' rings in the pipe fittings, reconnect the pipes to the oil-filter adaptor, tightening the fittings.





7. Install the pipe clips and torque the bolts to 2O Nm (l5 ft lb). Install and tighten the bolts in the sump and cylinder head.
8. Install the bracket for the alternator and servo pump.



9. Lift the bracket and steady bar for the servo pump into position. Swivel the alternator upwards and install the long bolt through the pump and alternator.
10. Install the two remaining securing bolts for the servo pump. Tighten all bolts securing the servo pump and bracket and also the alternator pivot bolt (socket head).
11. Install the steady-bar bolt in the timing cover. Remember the nut for the bolt.





12. Install the water-pump pulley.





13. Install the idler-wheel pulley and back plate for the automatic tensioner and leave the centre-bolt finger tight.





14. Lift the spring unit into position and tighten the securing bolts. Tighten the idler-wheel pulley centre-nut.





15. Install the crankshaft pulley and torque to 190 Nm (140 ft lb).





16. Install the multi-groove belt and check that the tensioner is operating properly.
17. Install and tension the AC belt.





18. Install the wing liner.











19. Install the road wheel. Check that the oil plug and coolant drain plug have been tightened. Lower the car.
20. Install the bolt for the coolant-pipe clip (underneath the inlet manifold).





21. Install the bracket and dipstick tube.





22. Remove locking segment 8393993.





23. Reconnect the battery.








24. Fill up the coolant and engine oil.
25. Check for leaks and that all systems are working properly.