11 31 Camshaft
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Tensioning rail and guide rail, cyl. 1 to 4, to crankcase | S63O 0 | M10x1.25 | Insert screws dry | 46 Nm |
| 2AZ Tensioning rail and guide rail, cyl. 5 to 8, to crankcase | S63O 0 | M8x1.25 | 20 Nm | |
| 3AZ Guide rail to cylinder head | S63O 0 | M14x1, 5 | Replace sealing ring | 25 Nm |
| 4AZ Sliding rail to cylinder head | S63O 0 | M7 | 15 Nm | |
| 5AZ Chain tensioner to cylinder head | S63O 0 | M7 | 13 Nm | |
| 6AZ Camshaft bearing cap to cylinder head | S63O 0 | M7 | 15 Nm | |
| 7AZ Camshaft step bearing cap to cylinder head | S63O 0 | M7 | 15 Nm |
TIGHTENING TORQUE SPECIFICATIONS - CAMSHAFT
11 15 Case Covers
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Connection to cylinder head cover | S63O 0 | M6 | 10 Nm | |
| 2AZ Heat shield to cylinder head cover | S63O 0 | M6 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - CASE COVERS
11 14 Case Covers
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Jump guard to crankcase | S63O 0 | M6 | 10 Nm | |
| 2AZ Gear case cover to crankcase, bottom | S63O 0 | M8 | 21 Nm | |
| 3AZ Gear case cover to cylinder head, top | S63O 0 | M6 | 10 Nm | |
| 4AZ End cover (oil) to crankcase (transmission side) | S63O 0 | M6 | Observe tightening sequence (liquid sealing compound required) | 10 Nm |
| 5AZ End cover (water) to crankcase (transmission side) | S63O 0 | M6 | Observe tightening sequence (liquid sealing compound required) | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - CASE COVERS
11 24 Connecting Rods and Bearings
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Connecting rod bolts | S63O 0 | M9 | Replace, wash and oil screws | |
| 1. Jointing torque | 5 Nm | |||
| 2. Jointing torque | 20 Nm | |||
| 3. Angle of rotation | 70 ° |
TIGHTENING TORQUE SPECIFICATIONS - CONNECTING RODS AND BEARINGS
11 51 Coolant pump
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Coolant pump to gear case. | S63O 0 | M6x25 M6x70 M6x90 | Replace gasket. | 10 Nm |
| 2AZ Coolant temperature sensor to coolant pump. | S63O 0 | M12 x 1.5 | 13 Nm | |
| 3AZ Supplementary coolant pump to bracket. | S63O 0 | K3.5x20 | 1, 5 Nm |
TIGHTENING TORQUE SPECIFICATIONS - COOLANT PUMP
11 21 Crankshaft and Bearings
| Type | Thread | Tightening specification | Measure | |
|---|---|---|---|---|
| 1AZ Increment wheel on crankshaft | S54 | M5 10.9 | Replace screws | |
| Jointing torque | 5.0 Nm | |||
| Torque angle | 45 ° | |||
| Increment wheel on crankshaft | M5 10.9 | Replace screws | 13 Nm | |
| Increment wheel on crankshaft | M5 8.8 | Replace screws | 5.5 Nm |
TIGHTENING TORQUE SPECIFICATIONS - CRANKSHAFT AND BEARINGS
11 12 Cylinder head with cylinder head cover
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Cylinder head bolt | S63O 0 | M11 x 1.5 | Replace screws. | |
| Jointing torque | 30 Nm | |||
| 1. Angle of rotation | 90 ° | |||
| 2. Angle of rotation | 90 ° | |||
| 2AZ Cylinder head bolt to gear case cover | S63O 0 | M8 | 23 Nm | |
| 3AZ Cylinder head cover to cylinder head. | S63O 0 | M6 | 10 Nm | |
| 4AZ Metal bracket to cylinder head. | S63O 0 | M6 | 8 Nm | |
| 5AZ Lifting eye to cylinder head. | S63O 0 | M8 | 22 Nm | |
| 6AZ Ignition coil cover to cylinder head cover. | S63O 0 | M6 | 4 Nm | |
| 7AZ Non-return valve | S63O 0 | M14x1, 5 | 20 Nm | |
| 8AZ Ventilation connection | S63O 0 | M8x1 | Replace sealing ring. | 15 Nm |
| 9AZ Oil filler neck to cylinder head cover. | S63O 0 | M6 | Replace sealing ring. | 14 Nm |
| 10AZ Screw plug to cylinder head | S63O 0 | M10x1 | Replace sealing ring. | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - CYLINDER HEAD WITH CYLINDER HEAD COVER
11 78 Emissions control, control sensor / monitoring sensor
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Control sensor / monitoring sensor | S63O 0 | M18 x 1.5 | 50 Nm | |
| 2AZ Bracket, oxygen sensor, to cylinder head cover | S63O 0 | M6 | 10 Nm | |
| 3AZ Support bridge to cylinder head cover | S63O 0 | M6 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - EMISSIONS CONTROL, CONTROL SENSOR / MONITORING SENSOR
| Type | Thread | Tightening specification | Measure | |
|---|---|---|---|---|
| 1AZ Control sensor / monitoring sensor | N74 | M18 x 1.5 | 50 Nm | |
| 2AZ Bracket, oxygen sensor, to cylinder head cover | N74 | M6 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - EMISSIONS CONTROL, CONTROL SENSOR / MONITORING SENSOR
11 78 Emissions-control, Lambda oxygen sensor
| Type | Thread | Tightening specification | Measure | |
|---|---|---|---|---|
| 1AZ Oxygen control sensor; oxygen monitor sensor | All | M18 x 1.5 | 50 Nm |
TIGHTENING TORQUE SPECIFICATIONS - EMISSIONS-CONTROL, LAMBDA OXYGEN SENSOR
11 11 Engine block
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Bearing cap to crankcase (ASA collar bolt) | S63O 0 | M11x102 | Replace screws. | |
| Jointing torque | 20 Nm | |||
| Angle of rotation | 100 ° | |||
| 2AZ Bearing cap to crankcase (ASA collar bolt 10.9) | S63O 0 | M8x70 | Replace screws. | |
| Jointing torque | 10 Nm | |||
| Angle of rotation | 55 ° | |||
| 3AZ Threaded support sleeves | S63O 0 | Jointing torque | 6 Nm | |
| 4AZ Angled screw connection to crankcase | S63O 0 | M8x37 | Flanged head screw 10.9 | 34 Nm |
| 5AZ Spacer bolt, oil pump | S63O 0 | M8 | 34 Nm | |
| 6AZ Screw plug, gutter strip | S63O 0 | M14x1, 5 | Replace gasket. | 25 Nm |
| 7AZ Screw plug, main oil gallery rear and in V-space right | S63O 0 | M18x1.5 | Replace gasket. | 25 Nm |
| 8AZ Oil nozzle to crankcase | S63O 0 | M12x1 | 10 Nm | |
| 9AZ Special tool to crankcase | S63O 0 | M8x35 | 20 Nm | |
| 10AZ Special tool to crankcase | S63O 0 | M10x35 | 40 Nm | |
| 10AZ Special tool 11 8 930 to special tool 00 2 300 | S63O 0 | M14x35 | 160 Nm |
TIGHTENING TORQUE SPECIFICATIONS - ENGINE BLOCK
11 62 Exhaust manifold
| Type | Thread | Tightening specification | Measure | |
|---|---|---|---|---|
| 1AZ Exhaust manifold to cylinder head Coat screw connections with CRC copper paste | All | M6 | Replace nuts | 10 Nm |
| M50 / M52 / M52TU / M54 / M56 / S52 / S50 US | M7 | Replace nuts | 20 Nm | |
| All / others | M7 | Replace nuts | 15 Nm | |
| M10 | M8 | Upper row of staybolts installed with bolt cement | 23 Nm | |
| M21 | M8 | Replace nuts Retighten after 2000 km Slacken nuts by a 1/4 turn | 12 Nm | |
| 12 Nm | ||||
| M41 / M47 / M47TU / M51 / M57 / M57TU | M8 | Replace nuts | 20 Nm | |
| All / others | M8 | Replace nuts | 23 Nm |
TIGHTENING TORQUE SPECIFICATIONS - EXHAUST MANIFOLD
11 52 Fan
| Type | Thread | Tightening specification | Measure | |
|---|---|---|---|---|
| 1AZ Fan clutch on water pump Coupling nut (left-hand threads) | All | 40 Nm | ||
| M54 | 45 Nm | |||
| 2AZ Fan to fan clutch | All | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - FAN
11 22 Flywheel
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Flywheel to crankshaft (automatic transmission) | S63O 0 | M12x1.5 | Replace screws | 105 Nm |
TIGHTENING TORQUE SPECIFICATIONS - FLYWHEEL
11 61 Intake manifold
| Type | Thread | Tightening specification | Measure | |
|---|---|---|---|---|
| 1AZ Intake manifold on cylinder head | All | M8 | 22 Nm | |
| All | M7 | 15 Nm | ||
| All | M6 | 10 Nm | ||
| 2AZ Soundproofing hood to holder | M60/1 / M60/2 / M62 | M6 | 8 Nm |
TIGHTENING TORQUE SPECIFICATIONS - INTAKE MANIFOLD
11 61 Intake plenum
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Intake manifold to cylinder head | S63O 0 | M7 | 15 Nm | |
| 2AZ Holder, intake module, to cylinder head | S63O 0 | M6 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - INTAKE PLENUM
11-42 Oil Filter and Lines
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Oil filter cover to oil sump upper part | S63O 0 | S88.5x3 | O-ring lightly oiled | |
| 1. Initial tightening | 30 Nm | |||
| 2. Release oil filter cover through | 180° | |||
| 3. Final torque | 40 Nm | |||
| 2AZ Oil drain plug to oil filter cover | S63O 0 | M12 | Replace sealing ring | 10 Nm |
| 3AZ Turbocharger oil line to crankcase | S63O 0 | M12x1.5 | Replace sealing ring | 27 Nm |
| 4AZ Oil line to turbocharger | S63O 0 | M10x1 | Replace sealing ring | 16 Nm |
| 5AZ Oil line to exhaust gas turbocharger (inlet) | S63O 0 | M6x16 | Replace seal | 10 Nm |
| 6AZ Oil line to oil return lid | S63O 0 | M6x14 | Replace seal | 10 Nm |
| 7AZ Holder, oil line to turbocharger | S63O 0 | M6 | Screw, non-captive | 10 Nm |
| 8AZ Oil return cover to crankcase | S63O 0 | M6x20 | Replace seal | 10 Nm |
| 9AZ Oil return line to turbocharger | S63O 0 | M6x16 | 10 Nm | |
| 10AZ Oil return line to oil return cover | S63O 0 | M6 | Screw, captive | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - OIL FILTER AND LINES
11 43 Oil filling
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Oil cooler thermostat to oil sump upper part | S63O 0 | M33x2 | 95 Nm |
TIGHTENING TORQUE SPECIFICATIONS - OIL FILLING
11 41 Oil pump with strainer and motor
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Intake manifold to oil pump | S63O 0 | M6 | 10 Nm | |
| 2AZ Oil pump to bearing cap | S63O 0 | M8 | 24 Nm | |
| 3AZ Oil pump cover to housing | S63O 0 | M6 | 10 Nm | |
| 4AZ Sprocket to oil pump | S63O 0 | M10 | Important - left-hand thread | |
| 1. Jointing torque | 20 Nm | |||
| 2. Angle of rotation | 40 ° | |||
| 5AZ Oil pump sprocket to hub | S63O 0 | M6 | 10 Nm | |
| 6AZ Oil deflector to oil pump | S63O 0 | M6 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - OIL PUMP WITH STRAINER AND MOTOR
11 13 Oil sump
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Oil drain plug | S63O 0 | M18 x 1.5 | Replace sealing ring | 40 Nm |
| 2AZ Oil sump upper section to crankcase | S63O 0 | M8 | 25 Nm | |
| 3AZ Oil sump, lower section to upper section | S63O 0 | M8 | Replace microencapsulated screws | 27 Nm |
| 4AZ Oil deflector to oil sump upper section | S63O 0 | M6 | 10 Nm | |
| 5AZ Screw plug, oil channel, to oil sump upper section | S63O 0 | M24x1.5 | Replace sealing ring | 50 Nm |
| 6AZ Oil condition sensor to lower oil sump section | S63O 0 | M6 | Replace O-ring | 8, 5 Nm |
| 7AZ Oil temperature regulator to oil sump upper part (control valve) | S63O 0 | M33x2 | Replace sealing ring | 100 Nm |
TIGHTENING TORQUE SPECIFICATIONS - OIL SUMP
11 00 Standard screw connection
| Type | Thread | Tightening specification | Measure | |
|---|---|---|---|---|
| 1AZ Screws and nuts | M5 | 5 Nm ± 0.5 | ||
| 2AZ Screws and nuts | M6 | 8 Nm ±±1 | ||
| 3AZ Screws and nuts | M7 | 13 Nm±2 | ||
| 4AZ Screws and nuts | M8 | 19 Nm±3 | ||
| 5AZ Screws and nuts | M10 | 38 Nm±5 | ||
| 6AZ Hose clamp, WAF 5 | 1.0 to 1.5 Nm | |||
| 7AZ Hose clamp, WAF 6 | 2.5 up to3.5 Nm |
TIGHTENING TORQUE SPECIFICATIONS - STANDARD SCREW CONNECTION
11 53 Thermostat and Connections
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Thermostat housing to coolant pump | S63O 0 | M6 | 10 Nm | |
| 2AZ Coolant line to turbocharger (supply) | S63O 0 | M14x1, 5 | 38 Nm | |
| 3AZ Coolant line to turbocharger (drain) | S63O 0 | M14x1, 5 | 38 Nm | |
| 4AZ Coolant line to turbocharger (supply) | S63O 0 | M6x16 | 10 Nm | |
| 5AZ Coolant line to turbocharger (drain) | S63O 0 | M6x16 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - THERMOSTAT AND CONNECTIONS
11 65 Turbocharger and Control
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Exhaust manifold to turbocharger (D80 V-band clamp). | S63O 0 | M8 | Replace V-band clamp | 13 Nm |
| 2AZ Turbocharger to primary catalyst (D108 V-band clamp). | S63O 0 | M8 | Replace V-band clamp | 13 Nm |
| 3AZ Heat shield to heat shield, side. | S63O 0 | M6 x 16 | 10 Nm | |
| 4AZ Heat shield to support. | S63O 0 | M6 x 16 | 10 Nm | |
| 5AZ Heat shield to heat shield, rear. | S63O 0 | M6 x 16 | 10 Nm | |
| 6AZ Vacuum reservoir to crankcase / cylinder head. | S63O 0 | M6 | 10 Nm | |
| 7AZ Heat shield to heat shield, rear. | S63O 0 | M6 | Screw, captive | 10 Nm |
| 8AZ Heat shield, bottom, to crankcase / oil return cover. | S63O 0 | M6 x 14 | 10 Nm | |
| 9AZ Heat shield to crankcase. | S63O 0 | M6 x 22 | 10 Nm | |
| 10AZ Heat shield turbocharger and alternator to cylinder head. | S63O 0 | M6 x 14 | 10 Nm | |
| 11AZ Bracket, electropneumatic pressure converter, to cylinder head. | S63O 0 | M6x18 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - TURBOCHARGER AND CONTROL
11 28 V-ribbed belt with Tension and Deflection Element
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Belt tensioner with deflection pulley to crankcase | S63O 0 | M10 | 40 Nm | |
| 2AZ Belt pulley to torsion vibration absorber | S63O 0 | M10 | 40 Nm |
TIGHTENING TORQUE SPECIFICATIONS - V-RIBBED BELT WITH TENSION AND DEFLECTION ELEMENT
11 66 Vacuum pump
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Vacuum pump to cylinder head (1-4) | S63O 0 | M6 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - VACUUM PUMP
11 36 Variable camshaft control
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ VANOS gear to inlet and A-camshaft (Contact surface on screw head must greased with mounting paste) | S63O 0 | M10x1 | Replace screw | |
| Jointing torque | 30 Nm | |||
| Angle of rotation | 90 ° | |||
| 2AZ Non-return valve VANOS to cylinder head | S63O 0 | M14 x 1.5 | 20 Nm | |
| 3AZ Solenoid valve holder to cylinder head | S63O 0 | M6 | 10 Nm |
TIGHTENING TORQUE SPECIFICATIONS - VARIABLE CAMSHAFT CONTROL
11 23 Vibration damper
| Type | Thread | Tightening specifications | Dimension | |
|---|---|---|---|---|
| 1AZ Hub to crankshaft (head surface oiled) | S63O 0 | M18x1.5 | Replace screw | |
| 1. Jointing torque | 100 Nm | |||
| 2. Angle of rotation | 60 ° | |||
| 3. Angle of rotation | 60 ° | |||
| 4. Angle of rotation | 60 ° |
TIGHTENING TORQUE SPECIFICATIONS - VIBRATION DAMPER