Engine, Disassembly and Assembly
Engine, disassembly and assembly
Note: If during engine repairs, metal shavings or large quantities of small metal particles - caused, for example, by partial seizure of crankshaft and conrod bearings - are found in the engine oil: To prevent consequential damage, besides thoroughly cleaning out the oil passages, you must also replace the oil cooler.
I
II
Part I
1. 45 Nm (33 ft. lbs.)
2. Engine support
3. 25 Nm (18 ft. lbs.)
4. Bracket
^ Attached to lower part of intake manifold
5. Pin 10 Nm
^ For engine cover
6. 20 Nm (15 ft. lbs.)
7. Camshaft drive belt guard, upper section
8. Camshaft drive belt guard, center section
9. Washer
10. Tensioner
^ Semi-automatic camshaft drive belt tensioning roller, Refer to Timing Belt Tensioner, Testing and Inspection
11. Camshaft drive belt
^ Mark engine direction of rotation before removing
^ Check for wear
^ Do not kink
^ Removing, installing and tensioning, Refer to Timing Belt Tensioner, Testing and Inspection
12. Camshaft drive belt guard, rear
13. O-ring
^ Always replace
14. Coolant pump
^ Check for free turning
^ Replace as an assembly if leaking or binding
^ Removing and installing, Refer to Water Pump, Service and Repair
15. 15 Nm (11 ft. lbs.)
16. Camshaft drive belt sprocket (crankshaft)
17. 90 Nm (66 ft. lbs.) plus additional 1/4 turn (90°)
^ Always replace
^ Threads and shoulder must be free of oil and grease
^ Counter-hold with 3415 to loosen and tighten
^ 90° additional angle can be measured with torque angle meter i.e., Hazet 6690
18. Camshaft drive belt guard - lower part
19. 10 Nm (7 ft. lbs.)
^ Always replace
20. Pulley
^ for A/C compressor
21. Pulley
^ for power steering pump
22. Ribbed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
^ Removing and installing, Refer to Drive Belt, Service and Repair
23. Belt pulley/vibration damper
^ Can only be installed in one position, holes are off-set
^ Note position when installing toothed belt, Refer to Timing Belt, Service and Repair, Camshaft Drive Belt, Service and Repair
24. 40 Nm (30 ft. lbs.)
25. Ribbed belt tensioner
^ Loosen ribbed belt by turning with open end wrench
Part II
1. Engine block
^ Sealing flange and flywheel/drive plate, Refer to Transmission and Drivetrain, Automatic Transaxle/Transmission, Flex Plate, Service and Repair
^ Crankshaft, removing and installing, Refer to Crankshaft, Engine, Service and Repair
^ Pistons and connecting rods: disassembly and assembly, Refer to Piston, Service and Repair
2. Knock sensor 1 -G61
^ Gold plated terminals at sensor and wiring connector
^ Checking:
Refer to Powertrain Management
3. 2-pin harness connector
^ Black
^ For knock sensor 1 -G61
^ Gold plated terminals at sensor and wiring connector
4. 20 Nm (15 ft. lbs.)
^ Tightening torque influences knock sensor function
5. 2-pin harness connector
^ For knock sensor 2 -G66
^ Gold plated terminals at sensor and wiring connector
6. Knock sensor (KS) 2 -G66
^ Gold plated terminals at sensor and wiring connector
^ Checking:
Refer to Powertrain Management
7. Oil dipstick tube
^ Remove to siphon oil
^ With bracket on lower intake manifold
8. Dipstick
^ Oil level must not be above MAX mark!
9. Coolant pipe
^ Coolant hose connection diagram, Refer to Cooling System, Diagram
10. 40 Nm
11. Bracket
^ For ignition coils
12. Bracket
^ Only engine code AEG
13. 10 Nm (7 ft. lbs.)
14. Oil filter bracket
15. 15 Nm (11 ft. lbs.) plus additional 1/4 turn (90°)
^ Always replace
^ 90° additional angle can be measured with torque angle meter i.e., Hazet 6690
16. Gasket
^ Always replace
^ Installs on top of oil cooler
17. Gasket
^ Always replace
18. Engine speed sensor
^ Checking:
Refer to Powertrain Management
19. Sealing ring
^ Replace if damaged
20. 25 Nm (18 ft. lbs.)
21. O-ring
^ Always replace
22. Oil filter
^ Loosen with strap wrench
^ Tighten by hand
^ Observe instructions on oil filter when installing
23. Oil cooler
^ Coat contact area to flange, outside the seal, with: AMV 188 100 02
^ Make sure clearance between adjacent components
^ See note, above
24. Connection
25. 15 Nm (11 ft. lbs.)
26. Coolant thermostat
^ Checking: heat-up thermostat in water
^ Opening starts approximately 86°C (187°F)
^ Ends approximately 102°C (216°F)
^ Opening lift: 7 mm (0.28 inch) minimum
27. 45 Nm (33 ft. lbs.)
28. Assembly bracket
^ For ribbed belt tensioning roller, Generator and power steering pump
^ For engine without A/C
^ Bracket for engine with A/C, removing and installing
Refer to Heating & Air Conditioning.