Engine Disassembling and Assembling
Engine Disassembly And AssemblyCAUTION!
^ If large amounts of metal shavings or small metal particles are found in the engine oil, caused by wear of the crankshaft main and connecting rod bearings, thoroughly clean the oil passages to remove contaminants and help prevent later damage.
^ The oil cooler, if contaminated, cannot be sufficiently cleaned and must be replaced.
I = part I
II = part II
III = part III
Part I
1 - Tensioner
2 - 25 Nm (18 ft lb)
3 - Tensioner lever
4 - Dust sleeve
5 - 10 Nm (7 ft lb)
6 - Drive belt guard, lower
7 - Drive belt guard, upper
8 - 45 Nm (33 ft lb)
9 - Tensioner pulley
10 - Toothed drive belt
^ Before removing, mark direction of rotation
^ Check for wear
^ Do not kink
^ Removing and installing - refer to Toothed Drive Belt, Removing and Installing.
11 - Drive belt guard
12 - Drive belt guard, rear
13 - Drive belt sprocket, intermediate shaft
14 - 80 Nm (59 ft lb)
^ To loosen and tighten use holding fixture 3036
15 - Drive belt sprocket, crankshaft
16 - 90 Nm (66 ft lb) plus additional 1/4-turn (90°)
^ Always replace
^ To loosen and tighten, use holding fixture 3099
^ Lubricate threads and shoulder
^ Turning additional 1/4-turn (90°) can be done in stages
17 - Pulley
^ For coolant pump
^ Version with ribbed belt
18 - Ribbed drive belt
^ Before removing, mark direction of rotation
^ Removing and installing - refer to Ribbed Drive Belt, Removing and Installing.
19 - Vibration damper, crankshaft
^ Also serves as pulley for ribbed drive belt
^ Assembly only possible in one position (holes are offset)
^ Toothed drive belt, installing - refer to Toothed Drive Belt, Removing and Installing.
20 - V-belt
^ Adjusting, - refer to Drive Belt.
21-Pulley
^ For coolant pump
^ Version for V-belt
22 - Pulley
^ For crankshaft
Part II
1 - Positive Crankcase Ventilation (PCV) valve
2 - 20 Nm (15 ft lb)
3 - Intake manifold, upper
4 - Gasket
^ Always replace
5 - Cap
^ Replace gasket if damaged
6 - 10 Nm (7 ft lb)
7 - Reinforcing strip
8 - Cylinder head cover
9 - Oil deflector
10 - Cylinder head bolt
^ Tightening and loosening sequence - refer to Cylinder Head Assembly, Service and Repair.
11 - Cylinder head cover gasket
^ Replace if damaged
12 - Cylinder head
^ Removing and installing - refer to Cylinder Head Assembly, Service and Repair.
^ When replaced, always replace engine coolant
13 - Cylinder head gasket
^ Always replace
^ Always replace engine coolant
14 - Lifting eye
15 - Camshaft drive sprocket
^ Position during installation of drive belt - refer to Toothed Drive Belt, Removing and Installing.
16 - Grommet
17 - Hose connection
^ From crankcase breather
Part III
1 - Cylinder block
^ Removing and installing sealing flange and flywheel or drive plate refer to Sealing Flange And Flywheel Or Drive Plate, Removing And Installing.
^ Removing and installing crankshaft - refer to Crankshaft Removing and Installing.
^ Disassembling and assembling pistons and connecting rods - refer to Pistons and Connecting Rods, Disassembling and Assembling.
2 - Woodruff key
^ Check for tight fit
3 - 0-ring
^ Always replace
4 - Engine ground connection
5 - 25 Nm (18 ft lb)
6 - Knock sensor
^ Checking - refer to Powertrain Management
7 - 20 Nm (15 ft lb)
^ Incorrect tightening torque can influence knock sensor function
8 - Ignition distributor
^ Installing - refer to Ignition System
9 - 25 Nm (18 ft lb)
10 - Clamp
11 - Gasket
^ Always replace
12 - Oil filter bracket
13 - Crankcase breather
14 - Oil cooler
^ Coat flange contact area, outside sealing ring, with sealer AMV 188 10002
^ Ensure clearance to surrounding components
^ Caution! - Replace if oil has been contaminated
15 - Oil filter
^ Loosen with strap wrench
^ Tighten by hand
^ Follow installation instructions on oil filter
16 - 10 Nm (7.5 ft lb)
17 - Engine speed (RPM) sensor
^ Checking - refer to Powertrain Management
18 - Support rings
19 - 20 Nm (15 ft lb) plus additional 1/4-turn (90°)
^ Always replace
20 - 30 Nm (22 ft lb)
21 - Tensioner
22 - Bracket
23 - Seal
^ Always replace
24 - Tensioner lever
25 - Hammer-head screw
26 - Coolant pump
^ Disassembling and assembling - refer to Cooling System
27 - Oil pan
28 - 20 Nm (15 ft lb)
^ Loosen or tighten bolts on flywheel side using tool 3185
29 - Bracket
^ For power steering pump
30 - Baffle plate
^ With gasket for oil pan
^ Replace if damaged
^ To remove, remove oil pump