Engine: Locations
Assembly overview
Note:
^ Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that the crankshaft bearings or connecting rod bearings are damaged. To prevent this from causing further damage, perform the following repairs: clean the oil passages thoroughly and replace the oil spray jets, the oil cooler and the oil filter.
^ For engines with engine codes BDC and BGD, the balancer shaft gear assembly must be adjusted.
Part I
1 - 45 Nm
2 - Engine bracket
3 - 25 Nm
4 - Bracket
5 - Clip
^ Not installed in all engines
6 - Toothed belt guard - upper part
7 - Toothed belt guard - middle part
8 - 20 Nm
9 - Washer
10 - Tensioning roller
11 - Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink.
12 - Rear toothed belt guard
13 - O-ring
^ Replace
14 - Coolant pump
^ Check for ease of movement
^ Replace completely if damaged and leaking
15 - 15 Nm
16 - Crankshaft toothed belt pulley
17 - 90 Nm plus 1/4 turn (90°)
^ Replace
^ Threads and shoulder must be free of oil and grease
^ Use counterhold 3415 to loosen and tighten
18 - Toothed belt guard - lower part
19 - 10 Nm
^ Replace
20 - Compressor clutch
^ For air conditioning compressor
21 - Belt pulley
^ For power steering pump
22 - Poly V-belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
23 - Belt pulley/vibration damper
^ Can only be installed in one position. Holes are off-set
^ Note position when installing toothed belt.
24 - Bolt
^ For bolts marked 8.8, tighten to 25 Nm
^ For bolts marked 10.9, tighten to 40 Nm
25 - Tensioning element for poly V-belt
^ Turn with open end wrench to relieve tension on poly V-belt.
Part II
1 - Connector
^ For Knock Sensor (KS) 1 -G61-
^ Contacts are gold plated.
^ Do not interchange
2 - Knock Sensor (KS) 1 -G61-
^ Contacts are gold plated
^ Contact surfaces of knock sensor and cylinder block must be clean and free of grease
3 - 20 Nm
^ Torque setting influences function of knock sensor
4 - Connector
^ For Knock Sensor (KS) 2 -G66-
^ Contacts are gold plated
^ Do not interchange
5 - Knock Sensor (KS) 2 -G66-
^ Contacts are gold plated
^ Contact surfaces of knock sensor and cylinder block must be clean and free of grease
6 - Guide
7 - Dipstick
^ Oil level must not be above max. mark!
8 - Coolant pipe
9 - 25 Nm
10 - Bracket
^ For ignition coil
11 - 10 Nm
12 - 10 Nm
13 - Bracket
14 - 10 Nm
15 - Seal
^ Replace
16 - Oil filter bracket
17 - 15 Nm plus 1/4 turn (90°)
^ Replace
18 - Seal
^ Replace
19 - Engine speed (RPM) sensor -G28-
20 - Seal
^ Replace if damaged
21 - Union
22 - 15 Nm
23 - Thermostat
^ Checking: Heat-up thermostat in water
- Opening begins: approx. 86° C
- Opening lift: min. 7 mm
24 - 45 Nm
25 - Compact bracket
^ For tensioning roller, Generator, power steering pump and air conditioning compressor
26 - Cylinder block