Engine Disassembling and Assembling

Note:
^ Replace oil cooler and thoroughly clean oil passages if you find metal shavings or small metal particles in the engine oil, caused, for example, by partial seizure of crankshaft and connecting rod bearings.
^ Faulty injector scan cause violent knocking noises in the engine which sound like faulty bearings. When this occurs, run the engine at idle and loosen injector line unions one after the other. If the knocking stops when a specific union is loosened, it is an indication that the respective injector is faulty.

Part I





1. Ribbed belt
^ Mark direction of engine rotation before removing
^ Check for wear
^ Do not kink
^ Removing and installing
^ Vehicles with A/C with additional idler pulley, removing and installing see Fig.5
2. 10 Nm (7 ft. lbs.) + 1/4 turn (90°) further
^ Always replace
^ Torque angle can be measured with Hazet 6690 torque angle meter, or equivalent
3. Belt pulley/vibration damper
^ Can only be installed in one position; holes are offset
4. 25 Nm (18 ft. lbs.)
5. Tensioning element
^ For ribbed belt
- Turn with 16 mm wrench to slacken ribbed belt.
6. Generator
7. Assembly bracket
^ For injection pump, generator and power steering pump
^ For vehicles with A/C
^ Assembly bracket for vehicles with A/C, removing and installing:
8. 45 Nm (33 ft. lbs.)
9. Banjo bolt
^ 30 Nm (22 ft. lbs.)
10. Seal
- Always replace
11. Pressure line
12. Pump
^ For power steering
^ Removing and installing:
13. Pulley
^ For power steering pump





Fig. 5 Idler pulley, removing and installing
Only for vehicles with A/C

Removing
- Remove sound dampener tray
- Remove ribbed belt.
- Pry off cover -1- using screwdriver.
- Remove mounting bolt -2- and remove pulley -3-.

Installing
- Position pulley -3- and tighten mounting bolt - 2
^ Tightening torque 25 Nm (18 ft. lbs.)
- Install ribbed belt.
- Install sound dampener tray.

Part II





1. 120 Nm (88 ft. lbs.) + 1/4 turn (90°) further
^ Always replace
^ Threads and shoulder must be free of oil and grease
^ To loosen and tighten, counter-hold with 3415
^ Torque angle can be measured with Hazet 6690 torque angle meter, or equivalent
2. 40 Nm (30 ft. lbs.) 1/4 turn (90°) further
^ Always replace
^ Torque angle can be measured with Hazet 6690 torque angle meter, or equivalent
3. 15 Nm (11 ft. lbs.)
4. 22 Nm (16 ft. lbs.)
5. Timing belt guard, lower section
6. 10 Nm (7 ft. lbs.)
7. Timing belt middle guard
8. 45 Nm (33 ft. lbs.)
9. Right engine bracket
10. Timing belt guard, upper section
11. Timing belt
^ Mark engine direction of rotation before removing
^ Check for wear
^ Do not kink
^ Removing, installing and tensioning.
12. Idler pulley
13. 20 Nm (15 ft. lbs.) + 1/4 turn (90°) further
^ Always replace
^ Torque angle can be measured with Hazet 6690 torque angle meter, or equivalent
14. 20 Nm (15 ft. lbs.)
15. 20 Nm (15 ft. lbs.)
16. 45 Nm (33 ft. lbs.)
^ To loosen and tighten, counter-hold using 3036
17. Camshaft sprocket
^ Remove using T40001 two-arm puller.
18. Tensioning roller
^ Semiautomatic toothed belt tensioning roller.
19. Idler pulley
20. Injection pump sprocket
^ Two piece construction
21. 30 Nm (22 ft. lbs.)
22. Timing belt guard, rear
23. Coolant pump
^ Check for easy movement.
^ Replace when damaged or leaking.
^ Removing and installing.
24. Idler pulley
^ Remove before removing coolant pump
^ Removing and installing.
25. Crankshaft timing belt sprocket
26. Bushing
^ with nut
27. Injection pump
^ Removing and installing:
28. Assembly bracket
^ For Diesel injection pump, generator and power steering pump.
^ For vehicles with A/C
^ Removing and installing:
29. 45 Nm (33 ft. lbs.)