Disassembling and Assembling

Engine - Disassembling / Assembling:

Engine, Disassembling and Assembling:

NOTES:
^ Always rep/ace seals and gaskets
^ If during repair work, metal shavings or large quantities of small metal particles are found in the engine oil - caused, for example, by partial seizure of the crankshaft and conrod bearings - then, beside thoroughly cleaning out the oil passages, replace the oil cooler

Front Of Engine - Drive Belt:

Part I:
1 - Bracket
2 - Tensioning element for tensioning roller
3 - Mounting screw for vibration damper with ribbed belt
^2ONm (15 ft lb)
ribbed belt pulley
^20 Nm (15 ft lb) + 1/4 turn (90°)
4 - 1O Nm (7 ft lb)
5 - Vibration damper mounting bolt
^ Loosen and tighten using 3419 Counter-hold Service and Repair
Screw length: 65 mm
^ Coat threads and bolt head contact surface with sealing paste: AMV 188 001 02
^ Tightening torque: 460 Nm (340 ft lb)
Screw length: 110 mm
^ Torque: 160 Nm (118 ft lb) + 1/2 turn (180°) further
^ 2 x 90° additional turns can be performed in stages.
6 - Vibration damper with ribbed belt pulley
^ 10.91 - on
^ Damper and sprocket can only be installed in one position
7 - V-belt
^ up to 09.91
^ for power steering pump
^ Check tension using thumb
Deflection: new and used V-belts approx. 5 mm
8 - V-belt
^ 10.91 - on
^ For Generator
^ Check tension using thumb:
max. deflection:
New ribbed belt approx. 2 mm
Used ribbed belt approx. 5 mm
^ Checking V-belt tension: vehicles with toothed rack tensioner
9 - Vibration damper with V-belt pulley
^ 10.91 - on
^ Damper and sprocket can only be installed in one position
10 - Ribbed belt
^ 10.91 - on
^ Mark direction of rotation before removing
^ Check for wear
^ Remove and install with 3299 lever Service and Repair
11 - Spacer sleeve
12 - Cover cap
13 - Idler wheel
14 - 40 Nm (30 ft lb)
15 - Tensioning lever
16 - Tensioner
17 - Tensioning roller mounting bolt

Timing Belt (up to 07.95):

Part II up to 07.95:
1 - Front toothed belt guard upper section
2 - 2O Nm (15 ft lb)
^ Tensioning roller mounting nut, 15 Nm (11 ft lb)
3 - Washer
^ With locking tab
4 - Tensioning roller
^ 10.91 - on
^ Removing, installing, tensioning toothed belt Service and Repair
5 - Camshaft sprocket mounting bolt
^ Observe steel type marking on bolt head:
8.8 = 85 Nm (63 ft lb)
10.9 = 100 Nm (74 ft lb)
^ Loosen and tighten using 3036 counter-hold
6 - Toothed belt
^ Removing and installing Service and Repair
7 - Camshaft sprocket
^ Note position when installing toothed belt Service and Repair
8 - 10 Nm (7 ft lb)
9 - Toothed belt guard - rear
^ To remove: take off vibration damper if necessary
10 - Crankshaft sprocket
11 - Idler wheel
12 - Front toothed belt guard - lower section
^ To remove: take off vibration damper if necessary

Timing Belt (from 08.95):

Part II, 08.95 - on
1 - Front toothed belt guard, upper section
2 -Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
^ Removing and installing Service and Repair
3 - Camshaft sprocket mounting bolt
^ Observe steel type marking on bolt head:
8.8 = 85 Nm (63 ft lb)
10.9 = 1OO Nm (74 ft lb)
^ Loosen and tighten using 3036 counter-hold
4 - Camshaft sprocket
^ Note position when installing toothed belt Service and Repair
5 - Rear toothed belt guard, upper section
6 - 2O Nm (l5 ft lb)
7 - Coolant pump
^ Without elongated holes
^ Check shaft for ease of movement
^ If damaged and leaking, replace assembly
8 - 0-ring
^ It leaking and damaged replace
9 - Rear toothed belt guard, lower section
10 - 10 Nm (7 ft lb)
11 - Tensioning roller
12 - Crankshaft sprocket
13 - Toothed belt guard

Cylinder Head Assembly:

Part III:
1 - Cap
2 - Oil filler tube
3 - Cover cap
4 - 10 Nm (7 ft lb)
5 - To stop plate
^ Breather hose secured with bracket to oil filler pipe item -2-
^ Ensure sufficient clearance to throttle valve housing
6 - Positive Crankcase Ventilation valve
7 - Sealing ring
^ Replace if damaged
8 - Cylinder head cover
^ With oil deflector
9 - Dished washer
10 - Upper sealing washer
^ Replace if damaged
11 - Cylinder head cover gasket
^ Replace if damaged
12 - Cylinder head bolt
^ Sequence when loosening and tightening Service and Repair
13 - 15 Nm (11 ft lb)
14 - Distributor
15 - 0-ring
^ Replace if damaged
16 - Retaining clip
17 - Cylinder head gasket
^ Replace
^ It replaced; completely replace coolant
18 - After-run coolant thermal switch F95 with Engine Coolant Temperature switch G2
^ Yellow, 4-pin
^ F95 Checking: Testing and Inspection
^ ECT switch, checking: Wiring diagrams
19 - Engine Coolant Temperature sensor (G62)
^ Blue, 2-pin
20 - Cylinder head
^ Removing and installing Service and Repair
21 - Woodruff key
^ Check for tight fit
22 - to junction on coolant expansion tank Service and Repair
23 - Intake manifold

Cylinder Block Assembly:

Part IV:
1 - 70 Nm (52 ft lb)
2 - Sealing ring
^ Replace
3 - Oil filter bracket
^ Installation position determined by fitted pin
^ With check valve for hydraulic lifters
4 - 0-ring
^ Replace if damaged
5 - From coolant pipe Service and Repair
6 - Oil collector
7 - Cylinder block
^ Disassembly and assembly: Service and Repair
8 - 2O Nm (15 ft lb) M8
^ Install bolt with hex head toward transmission side
9 - Oil pan
10 - Oil pan gasket
^ Replace
^ Do not attach with adhesive, ensure positioned correctly
11 - 1O Nm (7 ft lb)
^ Remove and install using socket 3249
^ With flywheel installed: turn flywheel so recess aligns with bolts
12 - 40 Nm (30 ft lb)
13 - Bracket
14 - 20 Nm (15 ft lb)
^ Mounted to cylinder head
15 - 20 Nm (15 ft lb)
16 - Oil filter
^ Loosen with oil filter socket 2067
^ Tighten by hand
^ Note instructions on filter when installing
17 - 25 Nm (18 ft lb)
18 - Oil cooler
^ Coal contact area to flange, outside seal with AMV 188 100 02
^ Ensure clearance to adjacent components
^ If during repair work, metal shavings or large quantities of small metal particles are found in the engine oil - caused, for example, by partial seizure of the crankshaft and conrod bearings - then, beside thoroughly cleaning out the oil passages, replace the oil cooler