Engine, Disassembling and Assembling

Engine, disassembling and assembling





Assembly overview

Note: If, when repairing an engine, metal shavings or large amounts of small metal particles are found in the engine oil, caused for example by partial seizure of crankshaft or connecting rod bearings, perform the following work sequences to prevent consequential damage once repairs are complete:

- Thoroughly clean oil passages
- Replace oil spray jets
- Replace oil cooler
- Replace oil filter





Part I

1. 45 Nm
2. Engine bracket
3. 25 Nm
4. Bracket
- Depending on version
5. Bracket
6. Hose clip
7. 10 Nm
- For engine cover
- Depending on version
8. 20 Nm
- Depending on version
9. Toothed belt guard, upper part
10. Toothed belt guard, center section
11. 20 Nm
12. Washer
13. Tensioning roller
- Checking semiautomatic toothed belt tensioning roller
14. Toothed belt
- Mark direction of rotation before removing
- Check for wear
- Do not kink
15. Rear toothed belt guard
16. Washer
- Note Part No.
17. O-ring
- Always replace
18. Coolant pump
- Check for ease of movement
- If damaged or leaking replace complete
19. 15 Nm
20. Crankshaft toothed belt sprocket
21. 90° Nm plus an additional 1/4 turn (90°)
- Always replace
- Threads and shoulder must be free of oil and grease
- Use counterhold tool 3415 to loosen and tighten
22. Toothed belt guard, lower part
23. 10 Nm
- Always replace
24. Electro-magnetic coupling
- Air conditioner compressor
25. Belt pulley
- For power steering pump
26. Poly V-belt
- Mark direction of rotation before removing
- Check for wear
- Do not kink
27. Belt pulley/vibration damper
28. 25 Nm
29. Tensioning element for poly V-belt





Part II

1. Knock Sensor KS) 1 -G61
- Gold plated contacts
2. Connector
- For Knock Sensor KS) 1 -G61
- Gold plated contacts
3. 20 Nm
- Torque setting influences function of knock sensor
4. Connector
- For Knock Sensor KS) 2 -G66
- Gold plated contacts
5. Knock Sensor KS) 2 -G66
- Gold plated contacts
6. Dipstick guide
7. Dipstick
- Oil level must not exceed Max mark!
8. Coolant pipe
- Depending on version
- Coolant hose connection diagram
9. 25 Nm
10. Bracket
- For ignition coil
11. Bracket
- Depending on version
12. 10 Nm
13. Bracket
- Depending on version
14. Bracket
- Depending on version
15. Bracket
- Depending on version
16. Oil filter bracket
17. 15 Nm plus an additional 1/4 turn (90°)
- Always replace
18. O-ring
- Always replace
19. Oil filter
- Loosen with strap wrench
- Tighten by hand
- Note instructions on filter when installing
20. 25 Nm
21. Oil cooler
- Coat contact surfaces to oil filter bracket outside the seal with AMV 188 100 02
- Ensure clearance to adjacent components
22. O-ring
- Always replace
23. Engine speed sender
24. O-ring
- Replace if damaged
25. 40 Nm
26. Union
27. 15 Nm
28. Thermostat
- Checking: Heat up thermostat in water
- Starts to open at approximately 86°C
- Opening stroke min. 7 mm
29. Hex socket head bolt, 45 Nm
30. Compact bracket
31. Cylinder block