Engine, Disassembling and Assembling

Engine, disassembling and assembling

Note:
^ If when repairing an engine, metal shavings or large amounts of small metal particles are found in the engine oil, caused for example by partial seizure of the crankshaft or conrod bearings, perform the following work sequences to prevent consequential damage once repairs are complete:
^ Thoroughly clean oil passages
^ Replace oil spray jets
^ Replace oil cooler
^ Replace oil filter
^ The balancer shaft gear assembly must be adjusted, Refer to Oil Pump, Service and Repair





I
II





Part I
1- 45 Nm
2- Engine bracket
3- 25 Nm
4- Retainer
5- Clamp
6- Toothed belt guard - upper part
7- Toothed belt guard - center section
8- 20 Nm
9- Washer
10- Tensioner
^ Checking semi-automatic toothed belt tensioning roller, Refer to Timing Belt Tensioner, Service and Repair
11- Toothed belt
12- Rear toothed belt guard
13- O-ring
^ Replace
14- Coolant pump
15- 15 Nm
16- Crankshaft toothed belt sprocket
17- 90 Nm 1/4 turn (90°) further
^ Replace
^ Threads and shoulder must be free of oil and grease
^ Use counter support tool 3415 to loosen and tighten
18- Toothed belt guard - lower part
19- 10 Nm
^ Replace
20- Electro-magnetic coupling
^ For air conditioning compressor
21- Belt pulley
^ For power steering pump
22- Ribbed belt
23- Belt pulley/vibration damper
24- 25 Nm
25- Tensioning element for ribbed belt





Part II
1- Connector
^ For Knock Sensor (KS) 1-G61-
^ Gold plated contacts
^ Do not interchange
Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations
2- Knock Sensor (KS) 1-G61
^ Gold plated contacts
3- 20 Nm
^ Torque setting influences function of knock sensor
4- Connector
^ For Knock Sensor (KS) 2-G66-
^ Gold plated contacts
^ Do not interchange
^ Electrical Wiring Diagrams, Troubleshooting & Component Locations
5- Knock Sensor (KS) 2-G66-
^ Gold plated contacts
6- Dipstick guide
7- Dipstick
8- Coolant pipe
9- 25 Nm
10- Retainer
^ For ignition coils with final output stages
11- 10 Nm
12- 10 Nm
13- Retainer
14- 10 Nm
15- Seal
^ Replace
16- Oil filter bracket
17- 15 Nm 1/4 turn (90°) further
^ Replace
18- Seal
^ Replace
19- Engine speed sensor
20- Seal
^ Replace if damaged
21- Connecting unions
22- 15 Nm
23- Coolant thermostat
^ Checking: Heat up thermostat in water
^ Starts to open at approximately 86°C
^ Opening stroke min. 7 mm
24- 45 Nm
25- Compact bracket
^ For ribbed belt tensioning roller, alternator, power steering vane and air conditioning compressor
26- Cylinder block