Engine, Disassembling and Assembling

Engine, disassembling and assembling

Note: If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or connecting rod bearings) are found in the engine oil, the oil passages must be cleaned thoroughly and the oil cooler replaced in order to prevent further damage.





Part I





1. Toothed belt guard, upper part
2. Toothed belt
3. 20 Nm plus an additional 1/8 turn (45°)
4. Tensioning roller
5. 100 Nm
6. 25 Nm
7. Camshaft pulley
8. Hub
9. 10 Nm
^ Always replace
10. Rear toothed belt guard
11. Sealing grommet
^ Replace if damaged.
12. Idler roller
13. Coolant pump
14. Crankshaft toothed belt gear
15. 120 Nm plus an additional 1/4 turn (90°)
16. 15 Nm
17. 20 Nm
18. Toothed belt guard, lower part
19. Belt pulley/vibration damper
^ Can only be installed in one position. Holes are offset
20. 10 Nm plus an additional 1/4 turn (90°)
21. Cover
22. Toothed belt guard, center section
23. 45 Nm
24. Engine bracket





Part II

1. Poly V-belt
2. 10 Nm plus an additional 1/4 turn (90°)
3. Belt pulley/vibration damper
^ Can only be installed in one position. Holes are offset
4. 25 Nm
5. Tensioning element for poly V-belt
6. Generator
7. Compact bracket
8. 45 Nm
^ Note tightening sequence; Refer to Fig.1.
9. Banjo bolt, 30 Nm
10. Seal
^ Always replace
11. Pressure line
12. Power steering pump
13. Belt pulley
^ For power steering pump





Part III
1. Cylinder block
2. 3.5 Nm
3. Bracket
^ For vacuum reservoir
4. Vacuum reservoir
5. 40 Nm
6. Seal
^ Always replace
7. Oil filter bracket
8. 15 Nm plus an additional 1/4 turn (90°)
^ Always replace
^ First install upper left and lower right bolt, then tighten four bolts diagonally
9. 15 Nm
10. Engine Speed (RPM) sensor -G28
11. Connection union
^ For thermostat
12. O-ring
^ Always replace
13. Thermostat
^ Checking: Heat-up thermostat in water.
^ Starts to open: approximately 85°C
^ Ends: approximately 105°C
^ Opening stroke: min. 7 mm
14. 45 Nm
^ Note tightening sequence; Refer to Fig 1.
15. Compact bracket
^ For Generator, air conditioning compressor and power steering pump
16. Oil pan





Fig. 1 Tightening sequence for compact bracket to cylinder block
Work sequence
^ Install compact bracket to cylinder block (observe dowel sleeves between compact bracket and cylinder block).
^ Tighten compact bracket in tightening sequence as follows:
1. Tighten bolt -A- to 45 Nm.
2. Tighten bolt -B- to 45 Nm.
3. Tighten bolt -C- to 45 Nm.
4. Tighten bolt -D- to 45 Nm
5. Tighten bolt -E- to 45 Nm.
6. Tighten bolt -F- to 45 Nm.