Cylinder Block Assembly: Service and Repair

Replacing crankcase

Preliminary work

1. Remove engine.
2. Remove wire harness for engine.
3. Remove the generator.
4. Remove power-steering pump.
5. Remove left additional assembly bracket -2- and right engine carrier -8-. There are still two dowel sleeves (not shown) on the additional assembly bracket.








6. Remove starter.
7. Remove knock sensors.
8. Remove cylinder heads.
9. Remove water pump.
10. Remove coolant regulator.
11. Remove guide and tensioning rails.
12. Remove crankshaft.
13. Remove oil spray jets on turbo engine and cap on naturally aspirated engine.
Information

Component overview








Replacing crankcase

ATTENTION Risk of damage to cylinder liners on new crankcase if the old pistons are used.
^ Piston separation could cause the dimensions of the old piston to be unacceptably large compared with the new cylinder bore.
^ Risk of piston and cylinder-liner scoring if old, worn pistons are used.
^ The piston rings on the pistons must always be replaced when replacing the crankcase.

ATTENTION Leaks due to components being at too low a temperature or at different temperatures!
^ If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
^ Components must have reached at least 17°C throughout.
^ Components must not be too hot (distortion).
^ Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.

Note: The bearing shells of the main and connecting-rod bearings must be replaced on vehicles with high mileage.

1. Remove coolant guide. To do this, remove 10 screws -arrows-.





Component overview for coolant guide








2. Remove coolant guide and remove seals. Clean sealing surfaces.
3. Re-fit crankcase. When doing so, watch out for dowel sleeves and studs.
4. Fit coolant guide with new seals.

Subsequent work

1. Assemble engine.
2. Install engine.