Disassembling and Assembling
Engine, disassembling and assembling
CAUTION!
^ The cylinder block is aluminum. The crankshaft and also the pistons must not be removed. Just loosening the main bearing caps will cause deformation of the cylinder block bearing pedestals.
^ Engine block bearing pedestal deformation will cause a reduction of the bearing clearance. Bearing damage could occur due to a different bearing clearance even if the shells are not replaced.
^ If the bearing cap bolts are loosened, the cylinder block must be replaced complete with the crankshaft and pistons. Measuring the main bearing clearance is not possible with normal workshop equipment
Part I: Toothed belt drive. Refer to Toothed belt drive.
Part II: Cylinder block. Refer to Cylinder Block.
Note:
^ When disassembling or assembling the engine, secure it to the assembly stand using engine bracket 6095.
^ The engine must not be set down on the oil sump as this will damage the liquid gasket between the upper and lower oil sump.
^ Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that the crankshaft bearings or conrod bearings are damaged. To prevent this from causing further damage, perform the following repairs:
- Thoroughly clean oil passages.
- Replace oil non-return valve.
- Replace oil sprayjets.
- Replace oil cooler.
- Replace oil filter.
Part I: Toothed belt drive
1 - 10 Nm
2 - Bearing sleeve
3 - 20 Nm + 1/4 turn (90° further)
^ Replace
4 - Washer
^ For tensioning roller
5 - 40 Nm
6 - Tensioning roller
7 - Tensioning lever
8 - 22 Nm
9 - 55 Nm
^ Replace
^ Oil threads and bolt head contact surface
10 - Securing plate
^ Replace
^ Observe installation position- side with lettering faces rear
11 - Right camshaft pulley.
^ Pull off camshaft with two arm puller T40001 and claw T40001/2
12 - 10 Nm
^ Insert with locking fluid D 000 600 A2
13 - Toothed belt guard, rear right
14 - Idler roller
15 - Pin, 6 Nm
16 - 15 Nm
17 - Coolant pump.
18 - Gasket
^ Replace
19 - Toothed belt guard, rear left
20 - 10 Nm
^ Insert with locking fluid D 000 600 A2
21 - 10 Nm
22 - Left camshaft pulley.
^ Pull off camshaft with two arm puller T40001 and claw T40001/2
23 - Securing plate
^ Replace
^ Observe installation position- side with lettering faces rear
24 - 55 Nm
^ Replace
^ Oil threads and bolt head contact surface
25 - Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
26 - Eccentric roller
27 - 45 Nm
28 - Crankshaft toothed belt pulley
^ Installation possible in one position only
^ Secure crankshaft with clamping bolt 3242.
29 - 200 Nm + 1/2 turn (180°) further
^ Replace
^ Do not oil
^ Turning further can be done in several stages
30 - Washer
^ For tensioning lever
31 - Tensioning element
Part II: Cylinder block
1 - 10 Nm
2 - Cover
^ With connection for crankcase breather
3 - Connecting hose
^ For crankcase breather
4 - Clip
5 - Baffle plate
^ With seal
^ Replace
6 - Oil return supply valve
^ For right cylinder head
7 - O-ring
^ Replace
8 - 20 Nm
^ Tightening torque influences function of knock sensor
9 - Knock Sensor (KS) 1 -G61 -
10 - Knock Sensor (KS) 2 -G66-
11 -S crew plug, 35 Nm
12 - Seal 4 Replace
13 - Engine mounting
14 - 50 Nm + 1/4 turn (90°) further
^ Replace
15 - Banjo bolt, 30 Nm
16 - 10 Nm
17 - Coolant drain pipe
18 - Cylinder block
19 - Thermostat.
20 - Thermostat housing
21 - Oil return supply valve
^ For left cylinder head