Engine Overviews
Engine Overviews
Do not bore, hone, grind or rework the cylinder bores with workshop tools. Reworking damages the surface of the cylinder bore.
• If large quantities of metal particles or abraded material are detected during engine repairs, it may mean the crankshaft or rod bearings are damaged. To prevent further damage, perform the following steps after the repair:
• Clean the oil passages.
• Replace the oil spray jets.
• Replace the oil cooler.
• Replace the oil filter.
I - => [ Ribbed Belt and Accessory Drive ]
II - => [ Toothed Belt, without a Divided Toothed Belt Guard ]
III - => [ Toothed Belt, with a Divided Toothed Belt Guard ]
IV - => [ Cylinder Block and Components ]
Ribbed Belt and Accessory Drive
1 Accessory Bracket
• Follow the tightening sequence, refer to => [ Accessory Bracket Bolt Tightening Sequence ].
2 Bolt
• 23 Nm
3 Nut
• 23 Nm
4 Generator
• Removing and installing.
• Moving the threaded bushings on the generator slightly to the rear will make is easier to install the generator.
5 Bolt
• 40 Nm
• Follow the tightening sequence, refer to => [ Accessory Bracket Bolt Tightening Sequence ].
6 Bushing
• Quantity: 2
7 Bolt
• 25 Nm
8 Air Conditioning (A/C) Compressor
• Removing and installing.
9 Ribbed Belt
• Mark the rotation direction with chalk or a felt-tip pen before removing.
• Check for wear.
• Do not kink.
• Removing and installing, refer to => [ Ribbed Belt ] Service and Repair.
10 Vibration Damper
• With the pulley for the ribbed belt.
11 Bolt
• 20 Nm + 90° (1/4) additional turn.
• Always replace.
12 Bolt
• 23 Nm
13 Belt Tensioner
• Rotate the tensioner using a open end wrench to release the tension on the ribbed belt.
Accessory Bracket Bolt Tightening Sequence
Toothed Belt, without a Divided Toothed Belt Guard
• Vehicles from 01.06 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover => [ (Item 25) Cover for the Toothed Belt Guard ] and the guard is divided in the engine mount bracket area. Vehicles with a divided toothed belt guard overview. Refer to => [ Toothed Belt, with a Divided Toothed Belt Guard ].
1 Bolt
• 10 Nm
2 Upper Toothed Belt Guard
3 Bolt
• 50 Nm + 180° (1/2) additional turn.
• Use a retainer (3036) to loosen and tighten.
4 Camshaft Sprocket
• Secured in place by a woodruff key.
5 Bolt
• 10 Nm
• Install using locking fluid.
6 Rear Toothed Belt Guard
7 Woodruff Key
• Make sure it is secure.
8 Nut
• 25 Nm
9 Belt Tensioner
10 Coolant Pump
• Removing and installing, refer to => [ Coolant Pump ] Service and Repair.
11 O-ring
• Always replace.
12 Bolt
• 25 Nm
13 Idler Roller
14 Bolt
• 15 Nm
15 Bolt
• 35 Nm
16 Idler Roller
17 Sealing Flange
18 Diamond Disc
• Always replace.
19 Crankshaft Toothed Belt Gear
• There must be no oil on the contact surfaces between the gear, diamond disc and crankshaft
• Only possible to install in one position.
20 Bolt
• 90 Nm + 90° (1/4) additional turn.
• Always replace
• Do not lubricate.
• Use the counter support (3415) to loosen and tighten.
21 Toothed Belt
• Before removing, mark the direction of rotation using chalk or a felt tip pen.
• Check for wear.
22 Lower Toothed Belt Guard
23 Engine Mount Bracket
24 Bolt
• 45 Nm
25 Cover for the Toothed Belt Guard
Toothed Belt, with a Divided Toothed Belt Guard
• Vehicles from 01.06 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover => [ (Item 25) Cover for the Toothed Belt Guard ] and the guard is divided in the engine mount bracket area. Vehicles without a divided toothed belt guard overview. Refer to => [ Toothed Belt, without a Divided Toothed Belt Guard ].
1 Bolt
• 10 Nm
2 Upper Toothed Belt Guard
3 Bolt
• 50 Nm + 180° (1/2) additional turn.
• Always replace.
• Use the retainer (3036) to loosen and tighten.
4 Camshaft Sprocket
• Installed position secured by the woodruff key.
5 Bolt
• 10 Nm
• Install using locking fluid.
6 Rear Toothed Belt Guard
7 Woodruff Key
• Make sure it is secure.
8 Nut
• 25 Nm
9 Belt Tensioner
10 Coolant Pump
• Removing and installing, refer to => [ Coolant Pump ] Service and Repair.
11 O-ring
• Always replace.
12 Bolt
• 25 Nm
13 Idler Roller
14 Bolt
• 15 Nm
15 Bolt
• 35 Nm
16 Idler Roller
17 Sealing Flange
18 Diamond Disc
• Always replace
19 Crankshaft Toothed Belt Gear
• There must be no oil on the contact surfaces between the toothed belt gear, diamond disc and crankshaft.
• Only possible to install in one position.
20 Bolt
• 90 Nm + 90° (1/4) additional turn.
• Always replace.
• Do not lubricate.
• Use the counter support (3415) to loosen and tighten.
21 Toothed Belt
• Before removing, mark the direction of rotation using chalk or a felt-tip marker.
• Check for wear.
22 Lower Toothed Belt Guard
23 Bolt
• 8 Nm
• Quantity: 7
24 Engine Mount Bracket
25 Bolt
• 45 Nm
Cylinder Block and Components
1 Knock Sensor 1 (G61)
• To remove, the coolant thermostat housing must be removed. Refer to => [ Coolant Thermostat Housing with Thermostat ] Coolant Thermostat Housing with Thermostat.
• Contacts are gold plated.
2 Bolt
• 20 Nm
• Tightening specifications affect function of knock sensor
3 Knock Sensor 2 (G66)
• It is necessary to remove the oil filter bracket first in order to remove the knock sensor 2. Refer to=> [ Oil Filter Bracket ] Service and Repair.
• Contacts are gold plated.
4 Wire Bracket
5 Bolt
6 Wire Bracket
7 Bolt
8 Gasket
• Always replace.
9 Oil Filter Bracket
• Overview, refer to => [ Oil Filter Bracket ] Service and Repair.
10 Bolt
• 15 Nm + 90° (1/4) additional turn.
• Always replace.
11 Intake Manifold Support
12 Bolt
13 Bolt
• 10 Nm
14 Engine Speed Sensor (G28)
15 Seal
• Always replace.
16 Bolt
• 15 Nm
17 Coolant Thermostat Housing with Coolant Thermostat
• Removing and installing, refer to => [ Coolant Thermostat Housing with Thermostat ] Coolant Thermostat Housing with Thermostat.
18 O-ring
• Always replace.
19 Bolt
• 40 Nm
20 Accessory Bracket