Assembly Overview

Assembly Overview







[ Part I - Assembly Overview ]

[ Part II - Assembly Overview ]

Part I - Assembly Overview






1 45 Nm

2 Engine support

3 23 Nm

4 Bracket

• For the power steering fluid reservoir

5 Upper toothed belt guard

6 Center toothed belt guard

7 20 Nm

8 Washer

9 Tensioning roller

• Checking the half automatic toothed belt tensioning roller, refer to => [ Half Automatic Toothed Belt Tensioning Roller, Checking ] Service and Repair

10 Toothed belt

• Mark direction of rotation before removing

• Check for wear

• Do not kink

• Removing and Installing, refer to => [ Toothed Belt, Removing and Installing ] Service and Repair

11 Rear toothed belt guard

12 O-ring

• Replace

13 Coolant pump

• Check for ease of movement

• Replace completely if damaged or leaking

• Removing and Installing, refer to => [ Coolant Pump, Removing and Installing ] Service and Repair

14 15 Nm

15 Crankshaft toothed belt sprocket

16 90 Nm + 90° (1/4 turn) additional turn

• Replace

• The threads and shoulder must be free of oil and grease

• Use counter-holder (3415) to loosen and tighten

17 Lower toothed belt guard

18 9 Nm

• Replace

19 Belt pulley

• For air conditioning compressor

20 Belt pulley

• For power steering pump

21 Ribbed belt

• Mark direction of rotation before removing

• Check for wear

• Do not kink

• Removing and Installing, refer to => [ Ribbed Belt, Removing and Installing ] Service and Repair

22 Belt pulley/vibration damper

• It is possible to install in one position only, the holes are offset asymmetrically.

• Note position when installing toothed belt => [ Toothed Belt, Removing and Installing ] Service and Repair

23 25 Nm

24 Ribbed belt tensioning damper

• To release tension on ribbed belt, swing using open-end wrench. Refer to => [ Ribbed Belt, Removing and Installing ] Service and Repair.

Part II - Assembly Overview






1 Knock sensor 1 (G61)

• Contacts gold plated

2 Connector

• For Knock Sensor (KS) 1 (G61)

• Contacts gold plated

3 20 Nm

• Tightening specifications affect function of knock sensor

4 Oil dipstick

• Oil level must not be above the max. mark!

• Marks => [ Oil Dipstick Markings ] Engine Oil

5 Funnel

6 Coolant line

• Coolant hose connection diagram => [ Coolant Hose Connection Diagram ] [1][2]Cooling System

7 25 Nm

8 Bracket

• for the ignition coil

9 Bracket

10 9 Nm

11 O-ring

• Replace

• No spare part for the engine speed sensor (G28) , => [ (Item 17) ]

12 Gasket

• Replace

13 9 Nm

14 Bracket

15 Oil Filter Bracket

• Assembly overview => [ Oil Filter Bracket with Attachments, Assembly Overview ] Service and Repair

16 15 Nm + 90° (1/4 turn) additional turn

• Replace

17 Engine speed sensor (G28)

18 Oil filter element

• Remove with tension strap

• Fasten by hand

• Observe installation instructions for oil filter

19 25 Nm

20 Engine oil cooler

• Coat the contact surface on the oil filter bracket outside of the seal with sealant (AMV 188 100 02).

• ensure sufficient clearance to surrounding components

• installed depending on the version

21 Connecting piece

22 15 Nm

23 Coolant thermostat

• Checking: Heat up thermostat in water

Starts to open: approximately 86 °C

Opening lift: minimum 7 mm

• Removing and Installing, refer to => [ Coolant Thermostat, Removing and Installing ] Service and Repair

24 45 Nm

25 Bracket for assemblies

• Tensioning roller, generator, power steering pump and A/C compressor

26 Cylinder block

• Sealing Flange and Flywheel/Drive Plate, Servicing, refer to => [ Sealing Flange and Flywheel/Drive Plate, Removing and Installing ] Service and Repair

• Crankshaft => [ Crankshaft ] Service and Repair

• Piston and connecting rod => [ Piston and Connecting Rod ] Removal and Replacement