Engine, Disassembling and Assembling: Overview
Section I
Section II
Notes:
- Use only assembly tool T10029 to pull and install the spark plug boots.
- To carry out assembly work, the engine must be attached to the mounting stand using engine brackets 3269.
- If large amounts of metal chips and rubbings caused by scoring damage such as crankshaft bearing and connecting rod bearing damage are discovered in the engine oil, it will be necessary to replace all oil splash nozzles, the oil return barrier, the oil cooler and the oil filter cartridge in addition to thorough cleaning of the oil passages to prevent subsequent damage.
Section I
1. Camshaft sprocket
- For roller chain - 18 -
2. Pickup wheel
- The bearing surface on the cam wheel and pickup wheel must be dry when installed
- For Camshaft Position (CMP) Sensor -G40-
3. Sprocket Bolt 100 Nm
- Coat contact surface of the bolt head with oil when installing
- Hold camshaft with open-end wrench SW 24 when removing and installing
4. Bearing bolt, 18 Nm
- For tension bar - 16 -
5. Oil seal
- Replace if damaged or leaky
6. Chain tensioner, 40 Nm
- For camshaft roller chain -18-
- Rotate engine only with chain tensioner installed
7. Tension bar
- For camshaft roller chain -18-
8. Sprocket
- For roller chain - 24
9. Camshaft roller chain
- Mark direction of travel (installation position) before removing
10. Sprocket Bolt 100 Nm
- Use locking bracket 3406 for tightening and loosening
11. Sprocket
- For camshaft roller chain 18-
- Install
12. Bolt 10 Nm
13. Chain tensioner with tension bar
- For roller chain - 24 -
- Before installation, release tension on the stop teeth in the chain tensioner with a small screwdriver and press the tension bar against the chain tensioner
- Rotate engine only with chain tensioner installed
14. Drive gear sprocket
- Seated in crankshaft
- Ground tooth for bearing parting line TDC cyl. 1
15. Roller chain
- Mark direction of travel (installation position) before removing
16. Sliding rail
- For roller chain - 24 -
- Remove together with roller chain
17. Bolt without collar, 10 Nm
- For sliding rail - 25 -
18. Bolt with collar, 10 Nm
- For sliding rail - 30 -
19. 20 Nm
- Use with "D6" thread locking compound
20 20 Nm
21. Sliding rail
- For camshaft roller chain 18-
22. 10 Nm
- Use with "D6" thread locking compound
23. Thrust washer
24. Intermediate shaft
Section II
1 10 Nm
2. Oil pump drive cover
3. O-Ring
- Always replace
- Coat with oil before assembly
4. Oil pump drive
5. Cylinder block
6. Intermediate shaft
7. Thrust washer
8. 10 Nm
- Insert with "D6" locking compound
9. Knock sensor 2 (G66)
10. 20 Nm
- Tightening torque has influence on the function of the knock sensor
11. Engine rpm sensor(G28)
12. Drive shaft
- For oil pump drive
13. O-Ring
- Always replace
14. Coolant pipe
15. Oil pump
- Disassembling and assembling
- Coat oil pressure pipe on engine block and oil pump housing with AMV 188 001 02
16. 25 Nm
17. Oil pan
18. Oil drain plug, 30 Nm
- Replace if leaking. See Parts Catalog for correct application. In some cases,seal and drain plug are combined; do not interchange with separate seal and drain plug.
19. Seal oil drain plug
- Always replace
20. 15 Nm
21. Oil cooler cover, 25 Nm
22. Oil cooler
- Coat contact surfaces outside the oil seal with AMV 188 001 02
- Check for free movement with the surrounding parts
23. Bracket
24. Oil filter housing
- Disassembling and assembling
25. Gasket
- Replace
- Note installation position
- Coat with oil before installing
26. Bracket
- For valve for two-stage intake pipe switch-over (N156)
27. Compact bracket
- For alternator, air conditioning compressor and power steering pump
28. Guide bolt, 25 Nm
29. Guide tube
- For oil dipstick
- Attached to intake pipe top section with bolt
30. Vibration damper
31. 100 Nm plus additional 1/4 turn (90 °)
- Always replace
- Use locking bracket 3406 for loosening and tightening
- Tighten with torque limiting wrench VAG 1601
32. 45 Nm
33. Engine bracket
34. 10 Nm
35. Oil dipstick
- Oil level must not exceed the max. mark.
36. Oil return barrier, 5 Nm
- Note installation position
- Clean if severely contaminated
Fig. 1 To loosen and tighten the mounting bolt, lock vibration damper in position with locking bracket 3406
Note: The mounting bolt for the vibration damper must be replaced.