Cylinder Block Assembly: Service and Repair

Component Notes and Information

NOTE: During service procedures, refer to the illustration above and the information below.

1 Bolt
- Tighten to: 10 Nm (7 ft lb)
2 Oil pump drive cover
3 O-ring
- Always replace
- Oil before assembling
4 Oil pump drive
5 Cylinder block
- Removing and installing sealing flange and flywheel/ drive plate: refer to Replacement. Service and Repair
- Removing and installing crankshaft, refer to Replacement. Service and Repair
- Disassembling and assembling pistons and conrods, refer to Replacement. Service and Repair
6 Intermediate shaft
7 Thrust washer
8 Bolt
- Tighten to: 10 Nm (7 ft lb)
- Install with D6 locking fluid
9 Knock sensor 2 -G66-
- Checking: refer to Repair Group 01
10 Bolt
- Tighten to: 20 Nm (15 ft lb)
- Tightening torque influences knock sensor function
11 O-ring
- Always replace if damaged
12 Engine Speed sensor -G28-
- Checking, refer to Powertrain Management
13 Gasket
- Always replace if damaged
- Coat sump flange/cylinder block flange with " D2 " before installing gasket
14 Coolant pipe
- To thermostat housing refer to Part 1, item -24-
- Removing and installing: refer to Cooling System.
15 O-ring
- Always replace
16 Oil pump
- Disassembly and assembly. Service and Repair
- Coat oil pressure line on block and oil pump housing with AMV 188 001 02
17 Bolt
- Tighten to: 25 Nm (18 ft lb)
18 Bolt
- Tighten to: 10 Nm (7 ft lb)
- Always replace
- Install with D6 locking fluid
19 Seal
- Always replace
20 Oil drain plug
- Tighten to: 30 Nm (22 ft lb)
21 Bolt
- Tighten to: 15 Nm (11 ft lb)
- Remove and install using 3249 socket
- With flywheel installed: turn flywheel until recess aligns with bolts
22 Oil pan
- Clean sealing surfaces before installing
23 Oil cooler cover
- Tighten to: 25 Nm (18 ft lb)
24 Oil cooler
- Coat contact area outside seal with AMV 188 100 02
- Ensure clearance with any adjacent components
25 Oil filter housing
- Disassembly and assembly. Service and Repair
26 Gasket
- Always replace
- Note installed position
- Oil before installing
27 Vibration damper
- Ribbed belt, removing and installing, refer to Replacement.Service and Repair
28 Bolt
- Tighten to: 120 Nm (89 ft lb) + 1/4 turn (90°) further
- Always replace
- Counter-hold using 3406 to loosen and tighten refer to Fig. 1 below.
29 Coolant pump
- Check shaft for ease of movement removing and installing: refer to Cooling System
30 Bolt
- Tighten to: 20 Nm (15 ft lb)
31 Pulley
- For coolant pump
32 Bolt
- Tighten to: 25 Nm (18 ft lb)
- Loosening and tightening: counterhold using a punch fed through the holes
33 Bolt
- Tighten to: 55 Nm (41 ft lb)
34 Guide tube
- For dipstick
- Bolted to intake manifold
35 Right engine bracket
36 Dipstick

CAUTION: Oil must NOT be above MAX mark on dipstick!

37 Oil check valve
- Tighten to: 5 Nm (44 inch lb)
- Note installed position
- Clean if contaminated

Procedures





Fig. 1 Holding Vibration Damper Using 3406 Counter-Hold Tool To Loosen Or Tighten Mounting Bolt
- Replace mounting bolt

CAUTION: Do not allow the crankshaft to turn while tightening the mounting bolt