Assembly Overview
Assembly overview
Note: If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or connecting rod damage) are found in the engine oil, the oil passages must be cleaned thoroughly and the oil cooler replaced in order to prevent further damage.
I -
II -
Part I
Note: From 08.00 a new tensioning roller and toothed belt gear are being installed for toothed belt drive. Tensioning roller must be adjusted in order to tension toothed belt.
1 - 10 Nm
^ Replace
2 - Toothed belt cover - center part
3 - Toothed belt cover - upper part
4 - Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
5 - 65 Nm
^ Use retainer 3036 to loosen and tighten
6 - Camshaft sprocket
^ Note installed position: Thin rib of camshaft gear points outward and TDC marking cylinder 1 is visible
7 - 27 Nm
8 - Tensioning roller
^ up to 07.00: not adjustable
9 - Washer
10 - Tensioning roller
^ from 08.00: must be adjusted using a pin wrench 3387
11 - Washer
12 - 27 Nm
13 - Tensioner for toothed belt
^ up to 07.00: secure with pin T40011
^ from 08.00: secure with a plate T10008
14 - 25 Nm
15 - Idler roller
16 - 15 Nm
17 - O-ring
^ replace if damaged
18 - Coolant pump
19 - 15 Nm
20 - Crankshaft toothed belt sprocket
21 - 90 Nm plus 1/4 turn (90°)
^ Replace
^ The threads and shoulder must be free of oil and grease
^ Use counter-holder 3415 to loosen and tighten
22 - Toothed belt cover - lower part
23 - Pulley
^ for viscous fan clutch
24 - Ribbed belt
^ Mark direction of rotation before removing
25 - Pulley
^ For power steering pump
26 - 25 Nm
27 - Belt pulley/harmonic balancer
^ for 2 belt drives
^ Only possible to install in one position - Bores are offset
^ Note position when installing toothed belt
28 - Ribbed belt tensioner
29 - Ribbed belt
^ For air conditioning compressor
^ Mark direction of rotation before removing
30 - Pulley
^ For air conditioning compressor
31 - 10 Nm plus 1/4 turn (90°)
^ Replace
32 - Tensioner for ribbed belt
^ To release tension on ribbed belt, swing using open-end wrench
33 - 25 Nm
34 - Pulley
^ For generator
Part II
1 - Knock Sensor (KS) 1 G61
2 - 20 Nm
^ Tightening torque affects function of Knock Sensor (KS)
3 - Knock Sensor (KS) 2 G66
4 - Oil dipstick
^ Oil level must not be above the max. mark!
5 - 20 Nm
6 - Lower coolant line
7 - Oil supply line
^ To turbocharger
8 - Oil filter bracket
^ Disassembling and assembling
9 - 15 Nm plus 1/4 turn (90°)
^ Replace
10 - Oil cooler
^ Coat contact surfaces to oil filter bracket outside seal with AMV 188 100 02
^ Ensure sufficient clearance to surrounding components
11 - 25 Nm
12 - Oil filter housing
^ Remove with tension strap
^ Fasten by hand
^ Observe installation instructions for oil filter
13 - Gasket
14 - 10 Nm
15 - Engine speed (RPM) sensor G28
16 - Connecting piece
17 - 15 Nm
18 - Left engine mount
19 - 40 Nm
20 - O-ring
^ Replace if damaged
21 - 45 Nm
22 - Coolant thermostat
^ Checking: Heat up thermostat in water
^ Opening begins approx. 86°C
^ Opening lift min. 7 mm
23 - 20 Nm
24 - Brace
^ Between bracket and intake manifold
25 - 50 Nm
^ Observe tightening sequence
26 - Bracket
27 - Oil pan
28 - 15 Nm
29 - Cylinder block
30 - 40 Nm
31 - Engine bracket, right