Engine, Disassembling and Assembling

Engine, disassembling and assembling

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 conrod 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

Only engine codes BDC, BGD
^ The balancer shaft gear assembly must be adjusted.





1. 45 Nm
2. Engine bracket
3. 25 Nm
4. Retainer
^ According to engine versions
5. Retainer
^ According to engine versions
6. Clamp
7. 10 Nm
^ For engine cover
^ According to engine versions
8. 20 Nm
^ According to engine versions
9. Toothed belt guard-upper part
10. Toothed belt guard, center section
11. 20 Nm
12. Washer
13. Tensioner
14. Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
15. Rear toothed belt guard
16. Washer
17. O-ring
^ Replace
18. Coolant pump
19. 15 Nm
20. Crankshaft toothed belt sprocket
21. 90 Nm + 1/4 turn (90°) further
^ Replace
^ Threads and shoulder must be free of oil and grease
^ Use counter support tool 3415 to loosen and tighten
22. Toothed belt guard, lower part
23. 10 Nm
^ Replace
24. Clutch
^ For air conditioning compressor
25. Belt pulley
^ For power steering pump
26. Ribbed 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 ribbed belt
^ Turn with open end wrench to loosen ribbed belt





Part II
1. Knock Sensor (KS) 1 -G61
^ Gold plated contacts
2. Connector
3. 20 Nm
^ Torque setting influences function of knock sensor
4. Connector
5. Knock Sensor (KS) 2 -G66
^ Gold plated contacts
6. Dipstick guide
7. Dipstick
8. Coolant pipe
9. 25 Nm
10. Retainer
^ For ignition coil
11. Retainer
^ According to engine versions
12. 10 Nm
13. Retainer
^ According to engine versions
14. Retainer
^ According to engine versions
15. Retainer
^ According to engine versions
16. Oil filter bracket
17. 15 Nm + 1/4 turn (90°) further
^ Replace
18. Seal
^ Replace
19. Oil filter
^ Loosen with strap wrench
^ Tighten by hand
^ Note instructions on filter when installing
20. 25 Nm
21. Oil cooler
22. Seal
^ Replace
23. Engine speed sensor
24. Seal
^ Replace if damaged
25. 40 Nm
26. Connecting unions
27. 15 Nm
28. Coolant thermostat
^ Checking: Heat up thermostat in water
^ Starts to open at approximately 86°C
^ Opening stroke: min. 7 mm
29. Hex socket head bolt
30. Compact bracket
31. Cylinder block