ASSEMBLY INSTRUCTIONS
Tightening sequence for thrust-bearing screws
Scheme 237
| Screws, bearing housing | |
|---|---|
| Initial tightening | 20 Nm (15 ft.lb.) |
| Final tightening | 1 x 90° turn |
TIGHTENING TORQUES - BEARING HOUSING WITH CRANKSHAFT
| No. | Designation | Qty. | Removal | Installation |
|---|---|---|---|---|
| 1 (1) | Hexagon-head bolt M6 x 35 | |||
| 3 | ||||
| 2 (1) | Guide rail | 1 | Check for wear marks and replace if necessary | |
| 3 (1) | Circlip | 1 | Replace; ensure correct seating | |
| 4 (1) | Washer | 1 | ||
| 5 (1) | Tensioning rail | 1 | ||
| 5a (1) | Lining for tensioning rail | 1 | Unclip | Check for wear marks and replace if necessary |
| 6 (1) | Intermediate shaft | 1 | ||
| 7 (1) | Chain for intermediate shaft drive | 1 | ||
| 8 (1) | Chain for camshaft drive of cylinder bank 1 - 3 | 1 | ||
| 9 (1) | Chain for camshaft drive of cylinder bank 4 - 6 | 1 | ||
| 10 (1) | O-ring 52 x 2.5 | 1 | Always replace; do not fit twisted | |
| 11 (1) | Pan-head screw M6 x 16 (micro-encapsulated) | 6 | Replace | |
| 12 (1) | Gasket | 1 | ||
| 13 (1) | Gasket | 1 | Ensure correct seating | |
| 14 (1) | Oil separator | Ensure correct seating | ||
| 15 (1) | Bearing housing, completely preassembled | 1 | Assemble on assembly fixture 9607 | |
| (1) For explanation (Scheme 241) | ||||
| (1) | For explanation (Scheme 241) |
REMOVAL AND INSTALLATION OF THRUST-BEARING SCREWS
Scheme 238
| No. | Procedure | Instructions |
|---|---|---|
| 1 | Checking sealing surfaces | Check both sealing surfaces of bearing housing for damage and cleanliness before installation in the bearing housing. Grind off sharp edges if necessary. |
| 2 | Checking flange bearing of intermediate shaft | Check flange for ease of movement or roughness of bearing; replace intermediate shaft if necessary. |
| 3 | Fitting O-ring | Carefully fit O-ring in the groove of the intermediate-shaft flange. Do not fit twisted. Grease lightly |
| 4 | Fitting chain for intermediate shaft | Put on chain between crankshaft drive sprocket and intermediate shaft drive sprocket. Fit guide rail and tensioning rail. After installation, turn intermediate shaft sprocket slightly by hand in clockwise direction and check whether there is sag in the upper chain area. Check chain installation if necessary. |
| 5 | Preparing intermediate shaft and crankshaft for installation | To facilitate assembly, connect the crankshaft and intermediate shaft with an O-ring before installing the complete bearing housing unit in the crankcase half (cylinder bank 1-3). |
CHECK PROCEDURE FOR BEARING HOUSING WITH CRANKSHAFT
Scheme 239
Scheme 240
Scheme 241
Scheme 242
Scheme 243
Scheme 244
Scheme 245
Scheme 246
Scheme 247
Scheme 248
Scheme 249
Scheme 250
Scheme 251
- Detach thrust plate or flywheel. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.
- Detach thrust plate and remove with drive plate. Detach and remove the flywheel.
- Clamp crankcase. Fasten engine holder, special tool 9589, to the crankcase half of cylinder bank 1 - 3.
- Turn primary chain tensioner out of the crankcase (cylinder bank 4 - 6).
- Loosen belt pulley. Undo hexagon-head bolt (M16 x 1.5 x 60) with special tool (socket wrench insert 9594); to do this, hold with holding device (special tool 9593).
- Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the locknut using the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.0 x 1.1 at the slotted threaded pin.
- Remove coolant guide housing.
- Undo fastening screws between crankcase half of cylinder bank 1-3 and bearing housing.
- Undo fastening screw between crankcase half of cylinder bank 4-6 and bearing housing.
- Turn crankcase by 180°. Undo oil pan fastening screws (M6 x 16, 13 ea.). Detach oil pan by tapping it at the sides with a plastic hammer. Remove air-oil separator. See «REMOVING AND INSTALLING AIR/OIL SEPARATOR»(ref-199829-S35860438682005102100000) .
- Turn crankcase 90° further. Crankcase half of cylinder bank 4 - 6 faces upward. Undo hexagon-head bolts (M6 x 35, 25 ea.) joining the crankcase halves.
- Carefully lift the crankcase half up and off. Do not tilt - this might damage the pistons.
- Mark pistons. Lever off front piston pin circlip. Push out piston pin.
- Fasten assembly fixture (special tool 9607) on the bearing housing with two M10 x 20 hexagon-head bolts.
Scheme 252
| Item | Designation | Special tool | Explanation |
|---|---|---|---|
| A | Retaining device for pistons and connecting rods for pre-fitting the piston pins of cylinder bank 1 - 3 | 9597 | |
| B | Assembly sleeves for pre-fitting the piston pin circlips | 9603 | |
| C | Assembly fixture for fitting piston pin circlips in assembly sleeve 9603 | 9500/3 | |
| E | Assembly tool for fitting the piston pins and piston pin circlips | 9602 | |
| E | Centering mandrel for fitting pistons in cylinder bank 4-6 | 9608 | |
| F | Piston ring restraining strap | ||
| G | Assembly aid for positioning the pistons | 9598 | |
| H | Fixing pin for fixing the belt pulley | 9595 | 1 set = 2 ea. (use short fixing pin) |
| I | Electric torch with mirror to check the piston pin circlips of cylinder bank 4-6 | Shop-made or, for example, illuminated adjustable mirror. |
SPECIAL TOOLS
ASSEMBLY
The cylinder heads differ in the area of the chain tensioners and are therefore marked on the front with 1-3 or 4-6 to prevent mix-ups.
Scheme 253
Scheme 254
Scheme 255
| Item | Designation | Special tool | Explanation |
|---|---|---|---|
| A (1) | Torque angle Torque wrench | ||
| B (1) | Socket wrench insert Torx T50 | 9633 | |
| Socket wrench insert Torx T55 | Commercially available | As of engine number M962065X02485 (modified cylinder head screws) | |
| (1) For explanation see scheme 556 | |||
| (1) | For explanation see scheme 556 |
SPECIAL TOOLS
- Fit cylinder head gaskets. NOTE: The gaskets are identified by Zyl. 1 - 3 or Zyl. 4 - 6 with OBEN/TOP, plus the corresponding part number. Ensure correct seating of dowel sleeves in crankcase. Put on gaskets.
Scheme 256
Scheme 257
| CAUTION | When working on the engine, absolute cleanliness is essential! An engine cover should be used on the engine assembly support. Lay removed engine parts on a clean base and cover them without fail. Even the smallest particles of dirt can block up oil bores. |
DISASSEMBLING AND ASSEMBLING INLET CAMSHAFT - AS OF MY 2003
| CAUTION | When working on the engine, absolute cleanliness is essential! An engine cover should be used on the engine assembly support. Lay removed engine parts on a clean base and cover them without fail. Even the smallest particles of dirt can block up oil bores. |
Presumable inlet camshaft before inserting in cylinder head
Scheme 258
| No. | Designation | Qty. | Removal | Installation |
|---|---|---|---|---|
| 1 (1) | Central screw | 1 | Replace | |
| 2 (1) | Adapter | 1 | Re-use | |
| 3 (1) | Camshaft adjustment device | 1 | Observe identification! | |
| 4 (1) | Diamond washer | 1 | Replace | |
| 5 (1) | Bearing sleeve | 1 | Pay attention to the installation position! Inscription should face towards camshaft | |
| 6 (1) | Inlet camshaft | 1 | Do not damage rotor cover | Do not damage rotor cover |
| 7 (1) | Rectangular rings | 2 | ||
| (1) For explanation see scheme 569 | ||||
| (1) | For explanation see scheme 569 |
REMOVAL AND INSTALLATION PROCEDURE FOR INLET CAMSHAFT (AS OF MY 2003)
DISASSEMBLING INLET CAMSHAFT
- Unscrew the central screw (1) with adapter (2). see scheme 569
- Remove camshaft adjustment device (3). see scheme 569
- Remove washer (4). see scheme 569
- Pull bearing sleeve (5) carefully off the camshaft. see scheme 569
ASSEMBLING INLET CAMSHAFT
Note. During assembly, absolute cleanliness is essential! The identification on the bearing sleeve should point towards the camshaft. see scheme 569 Check the pistons or rectangular rings for excavations and other damage to the contact surfaces of the camshaft and replace if necessary.
Scheme 259
- Install the bearing sleeve: lightly oil running surface with engine oil. Press together the first piston ring and carefully push up the bearing sleeve. Proceed in the same way with the second piston ring. NOTE: Make sure that the washer is inserted.
- Position the washer and place the camshaft adjustment device in position. Insert the central screw with the adapter and tighten gently by hand.
Pairing numbers or identification for cylinder head, cylinder head cover and camshaft bearing saddles.
The cylinder head, cylinder head cover and camshaft bearing saddles are machined together and must therefore always be installed together. Observe pairing numbers.
Scheme 260
- Pairing number of cylinder head cover
- Pairing number of cylinder head
- Pairing number of the two bearing saddles
Scheme 261
Note. The letters E or A before pairing numbers mean: E = Bearing saddle for inlet camshaft A = Bearing saddle for exhaust camshaft
Presumable camshafts
The inlet camshaft, exhaust camshaft, chain tensioner and chain must be preassembled before installation in the cylinder head.
ASSEMBLY WORK FROM BELOW
| No. | Procedure | Instruction |
|---|---|---|
| Remove underside panel | ||
| 1 (1) | Clamp shut coolant hoses | Clamp shut coolant hoses with hose clamps by Saltus, order numbers 3093 and 3094. |
| 2 (1) | Drain coolant | Undo drain plug at water guide housing and collect coolant |
| 3 (1) | Undo spring-band clamps | Undo spring-band clamps with pliers type MUBEA G0 - 190 |
| (1) For explanation see scheme 874 | ||
| (1) | For explanation see scheme 874 |
COOLANT PUMP ASSEMBLY WORK FROM BELOW
ASSEMBLY WORK FROM ABOVE
| No. | Procedure | Instruction |
|---|---|---|
| Remove right-hand seat | Disconnect electrical plug connection. Undo four Torx screws with socket E12 (3/8 inch). | |
| 4 (1) | Remove service cover at passenger compartment rear wall | Remove rear-wall lining. Undo nine hexagon-head bolts (wrench size 10 mm) and remove cover. |
| 5 (1) | Remove drive belt | Mark belt travel direction with a colored pen. Slacken belt, turning the tensioning pulley (wrench size 19 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys. Visually check state of belt and replace if necessary. |
| 6 (1) | Remove coolant pump | Undo hexagon-head bolts. The lower right hexagon-head bolt is difficult to reach. To undo it, use flexible-head socket wrench 4001 - 10 by Stahlwille. |
| 7 (1) | Separate metal seal | Cut old metal seal between coolant pump and water guide housing at the connecting webs. |
| (1) For explanation see scheme 874 | ||
| (1) | For explanation see scheme 874 |
COOLANT PUMP ASSEMBLY WORK FROM ABOVE