Engine Components - Removal, Replacement and Installation: Other Volvo V40 I рестайлинг

Replacing spark plugs

Special tools

9995702

Removing

1. Remove both engine covers.
2. Disconnect the connectors.
3. Disconnect the HT lead.
4. Remove the mounting screws.
5. Pull off the ignition coils.
6. Remove the spark plug with special tool «9995702»(ref-403953-S02394441542011061500000) .

Installing

1. Check the rubber and the spring inside. Replace if necessary.
2. Check the spark gap: 0.7-0.8 mm.
3. Install the spark plugs. Screw the spark plugs in until the gasket is pressed against the cylinder head. Tightening torque 25 Nm . Use special tool «9995702»(ref-403953-S02394441542011061500000) .
4. Position the ignition coils. Press the ignition coils into place.
5. Tighten the screw. Tightening torque 10 Nm .
6. Connect the high tension cables.
7. Reconnect the connectors. NOTE: The gray connector is for the left coil (cylinders 2 and 3), the blue connector is for the right coil (cylinders 1 and 4).
8. Check the function.
9. Install both engine covers.

Scheme 23

Remove

1. the cover over the throttle cable.
2. the idle air control (IAC) valve connector.
3. the two screws.
4. the idle air control (IAC) valve and the gasket from the intake manifold.

Always use a new gasket.

1. Locate the new gasket. The tab must be pointing downwards to the right.
2. Tighten the idle air control (IAC) valve. Tightening torque 10 Nm .
3. Reconnect the connector.
4. Check the function.
5. Reinstall the cover over the throttle cable.

Start the engine. Read off any diagnostic trouble codes (DTCs).

Scheme 24

1. Remove the clamp and the air intake hose. Use a twisting movement.
2. Disconnect the connector.
3. Remove the two Tx 25 screws.
4. Remove the mass air flow (MAF) sensor.
5. Remove the O-ring.

1. Install a new O-ring.
2. Position the mass air flow (MAF) sensor with the connector upward.
3. Tighten the screws.
4. Connect the connector.
5. Clean the air intake hose. Press the air intake hose firmly into place on the mass air flow (MAF) sensor.
6. Tighten the clamp.
7. Check the function.

Scheme 25

Removing/disconnecting

1. The connector.
2. The turbocharger (TC) control valve from the air cleaner (ACL) housing.
3. The clamps and hoses on the valve.

Note. Note how the hoses are connected.

HINT: If it is difficult to pull off the hose: Cut the hose along its length at the connection.

Installing/reconnecting

1. The hoses in their original positions. The clamps. Red (on the intake pressure side) Yellow (to the boost pressure control (BPC) valve) White (to the by-pass valve)
2. The valve to the air cleaner (ACL) housing
3. The connector.

Scheme 26

Remove

1. the upper timing cover.

Scheme 27

Remove

1. the connector
2. the screws
3. the valve
4. the gasket.

Note. Clean the area around the variable valve timing (VVT) valve thoroughly to avoid contaminated oil entering the ducts/the variable valve timing (VVT) valve.

Install the cover on the timing gear

See Installing the cover on top of the engine .

Start the engine. Check for leakage.

Camshaft seals, replacing

Special tools

9995006

9995383

9995460

9995452

9995651

9995451

9995199

9995718

9995719

Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Note. Crankshaft and camshafts must not be turned more than is stated in the method description. If the shafts are turned in any other way, the valves may be damaged.

Preparations

Remove

1. the cable from the battery's negative terminal. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000) .
2. the inlet hose between air filter and throttle housing. Put it aside.

Scheme 28

Remove

1. the brake servo's vacuum hose from its connection in the throttle housing. Loosen the hose by pressing down the plastic ring at the same time as the hose is pulled upwards. Move the hose aside.
2. the fuel line and cabling from its clips in the cylinder head's trailing edge.

Scheme 29

Remove

1. the cable channel's screws.
2. camshaft's rear cover.
3. the camshaft position (CMP) sensor housing
4. the trigger wheel.
5. right engine protection cover (only turbo).
6. the auxiliaries belt

Scheme 30

Remove

1. the upper timing cover.
2. the front timing cover.

Scheme 31

Loosen the servo hose's plate bracket from the auxiliary unit's rotation guard.

Scheme 32

Place lift tool 9995006 slightly in front of the engine's front lifting eye. Use lift arm 9995383 and lift hook 9995460 to lift the engine a few mm at the leading edge.

Scheme 33

Remove

1. the servo reservoir's screws.
2. the engine mount's screws.
3. the engine mounting.
4. the lower timing cover.

Scheme 34

Remove the right front wheel.

Position the upper timing cover.

Turn the crankshaft until the markings on the crankshaft and camshaft gear match.

Turn another 1/4 turns clockwise on the crankshaft and then back until the markings match. Markings are shown. Remove the upper timing gear cover.

Scheme 35

Slacken off the center screw for the belt tensioner slightly.

Hold and fixate the centre screw. Turn the tensioner's eccentric clockwise using a 6 mm Allen key to 10 o'clock.

Remove the timing belt from the camshaft gears.

Scheme 36

Timing gear pulleys with variable valve timing unit

1. Install camshaft adjustment tool «9995452»(ref-403953-S02369714572011061000000) at the rear of the camshafts.

Scheme 37

Timing gear pulleys with variable valve timing unit

1. Remove the plug at the front edge of the variable valve timing unit (TORX 55).
2. Remove the centre screw in the VVT-unit (TORX 55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit. A small amount of oil may run out. Place paper underneath.

Scheme 38

Timing gear pulleys without variable valve timing units

1. Remove the timing gear pulley's screws. Use counterhold «9995199»(ref-403953-S15123702502011061000000) .
2. Remove timing gear pulley.
3. Remove tool «9995452»(ref-403953-S02369714572011061000000) .
4. Remove the screw that holds the inner timing gear cover to the cylinder head.

Scheme 39

Carefully press in tool 9995651 between the sealing ring and the camshaft.

Carefully pry out the seal.

Oil the new seal.

Scheme 40

Install the new seal for the camshaft with VVT using drift 9995718 .

Install the new seal for the camshaft without VVT using drift 9995719 .

Install the screw holding the inner timing cover to the cylinder head.

Secure the crankshaft position

Install the adjustment tool.

Remove

1. front air baffle.
2. the support between the cylinder block and the intake manifold.
3. the starter motor mounting screws.

Place the starter motor to one side.

Remove the blind cover plug and the sealing washer.

Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.

Scheme 41

Install gauge 9995451 . Make sure that the gauge bottoms against the engine block.

Turn the crankshaft back counter-clockwise until it stops against the drift.

Scheme 42

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Scheme 43

Timing gear pulley without VVT

1. install upper timing cover.
2. install timing gear pulley without VVT on the camshaft. Use two screws positioned so that the markings on the timing belt gears/upper timing gear cover match. Do not tighten.

Timing gear pulley VVT

1. Install the timing gear pulley with the center screw on the camshaft. Make sure that the markings on the timing gear pulleys/upper timing gear cover match, but do not tighten.

Scheme 44

Install the timing belt on the timing gear pulleys.

Note. Adjust so that the screws in the timing gear pulley without variable valve timing do not reach the limit position in the oval holes.

Tension the timing belt

Scheme 45

Note. This adjustment is to be made with a cold engine. Suitable temperature is approximately 20°C/67°F. At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.

The image shows the indicator position at different engine temperatures.

Scheme 46

1. The belt shall be tight between the inlet camshaft gear, idler gear, and crankshaft.
2. Fix the belt tensioner centre screw in position and turn the belt tensioner eccentric counter clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window
3. Hold the eccentric secure and tighten the center screw. Torque tighten to 20 Nm .

Installing the timing covers

Install

1. lower timing gear cover.
2. the front timing gear cover. Tightening torque 12 Nm .
3. the upper timing cover.

Installing the right-hand engine mounting

Screw down the engine mount against the engine. Tightening torque 67 Nm .

Install

1. the screws on the body frame's console. Tighten with 50 Nm .

Finishing

Remove lifting beam and lifting hook.

Install

1. the servo reservoir.
2. servo hose's metal console on the auxiliary unit belt's rotation guard.
3. the auxiliaries belt
4. turbo engines: right engine protection cover as well as the cover over right headlight unit.
5. rear camshaft cover.
6. blinder. Tightening torque 17 Nm .
7. camshaft sensor housing. Tightening torque 5 Nm .
8. cable channel.
9. brake servo's vacuum hose.
10. hose between inlet pipe and air filter housing.
11. the blind cover plug.
12. the starter motor mounting screws.
13. the support between the cylinder block and the intake manifold.
14. front air baffle.
15. the cable from the battery's negative terminal. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000) .

Checking work

Function test

1. Carry out a road test.

Crankshaft seal rear, replacing

Special tools

9995112

9995651

9991801

9995678

9997174

9512050

Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Scheme 47

Remove the gearbox

1. See «Removal»(ref-441309-S18284716132011121500000) .

Remove the flywheel/carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Scheme 48

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Scheme 49

Note. To clean the crankshaft, use cloth 9511024.

Installing the sealing ring

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Scheme 50

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool: 9997174 . Discard the old screws for the flywheel.

Scheme 51

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as shown. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel/carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel/carrier plate.

1. Install the other screws. Tighten crosswise to 45 Nm .
2. Replace the 3x special screws with new standard screws. Tighten crosswise to 45 Nm .
3. Then angle-tighten all 10x screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Flywheel: 65° . Carrier plate 50° .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Installing the gearbox

Install the transmission

1. See «Installation»(ref-441309-S03716458932011121500000) .

Checking the engine

Test drive the car to check the function of the engine and the gearbox.

Gearbox, fitting

Special tools

9512661

9995460

9995972

9995383

Position the gearbox against the engine

Scheme 52

Position the gearbox in the assembly position on support 9995972 and secure it with the brackets.

Apply a little grease, part number 1161246-2, to the clutch shaft.

Grease the splines (RH drive shaft) on the gearbox using part number 1161035-9.

Press the gearbox towards the engine along the clutch plate splines, and press on the right-hand drive shaft onto the splines.

Note. Position the starter motor on the adjustment bushing.

Secure the gearbox to the engine

Scheme 53

Thread the four retaining bolts and tighten to 50 Nm .

Remove the support 9995972 .

D4192T.

Press on the gearbox/engine mounting and secure with four bolts. Tightening torque 27 Nm .

Attach the gearbox mounting to the side of the body.

Scheme 54

Fit the mounting to the gearbox and secure with three bolts.

Use lifting hook 9995460 to lift the engine and fit the bolt to the chassis support.

Fit the three bolts and tighten to 45 Nm .

Lower the engine until the lifting brace no longer supports it.

Tighten the bolt on the side of the body to 98 Nm .

Note. Be careful of the hydraulic pipe to the clutch.

Diesel cars: Fit the fuel filter

Scheme 55

Position the fuel filter.

Fit the two nuts and tighten to 21 Nm .

Remove the lifting brace

Scheme 56

Remove the lifting hooks 9995460 , lifting brace 9995006 and support 9995383 .

Fit the retaining bolts to the top side of the gearbox

Scheme 57

Thread the bolts and tighten to 50 Nm .

Diesel cars

Position the cable harness support on the gearbox and fit the bolt.

Tighten to 50 Nm .

Fit the starter motor

Scheme 58

Position the starter motor and thread the three bolts.

Tighten the bolts to 50 Nm .

Fit the left-hand drive shaft

Scheme 59

Raise the car

Remove the protector from the tripod and opening in the gearbox.

Turn the steering wheel to the right to full lock.

Carefully fit the drive shaft into the differential.

Turn the steering wheel to the left and fit the lower adjustment bolt to the attachment point for the shock absorber/wheel axle.

Position the bellows.

Fit the three bolts and tighten to 25 Nm .

Secure the wheel axle to the shock absorber.

Scheme 60

Fit the upper bolt.

Tighten the two bolts to 90 Nm .

Insert the brake pipe into the support and fit the lock clip.

Fit the ABS line to the support.

Connect the lead to the reversing light switch

Scheme 61

Clean the connector first.

Connect the gearbox ground cable

Scheme 62

Clean the contact surfaces thoroughly.

Fit the cable and tighten to 40 Nm .

Diesel cars: Fit the intercooler

Scheme 63

Position the intercooler and thread the three bolts.

Tighten the bolts to 25 Nm .

Fit the right-hand drive shaft and speedometer cable to the gearbox

Scheme 64

If the drilled hole in the end pointing towards the gearbox is at the bottom (down in the space between two splines), the equivalent hole in the half-shaft must be at the top (crown), and vice versa.

Fit the two new locking pins to the drive shaft.

Fit a new O-ring to the speedometer cable and tighten.

Insert the wire fully into the housing and fit a circlip.

Fit the wheel

Scheme 65

Check that the contact surfaces of the brake disc and brake pads are clean.

Grease the central hub guide pin in front of the brake pad with corrosion inhibitor, part number 1161038-3.

Position the wheel and loosely tighten the bolts.

Then tighten diagonally opposite bolts alternately to 110 Nm .

When tightening with a percussion wrench, torque socket 9512661 must be used.

Retighten by hand.

Fit the hub cap.

Fit the gear selector rod

Scheme 66

Grease moving parts with Volvo grease, part number 1161241-3.

Check the rubber parts.

Position the gear selector rod and thread the bolt.

Tighten the bolt to 16 Nm .

Fit the central longitudinal member

Scheme 67

Fit the engine mounting to the engine support point.

Fit the two bolts (correct size).

Fit the four bolts

1. front: long bolts
2. rear: short bolts.

Tighten the bolts to

1. on body side, 69 Nm
2. on engine side, 52 Nm .

First, tighten the rear bolts and then the front bolts.

Fit the heat shield

Scheme 68

Position the heat shield and thread the first bolt (A).

Fit the two other bolts.

Tighten the bolts to 10 Nm .

Fill the gearbox with oil

Scheme 69

Position a receptacle to catch any spills.

Remove the filler/level plug.

Fill the gearbox with oil, part number 1161681, up to the edge of the filler orifice.

Fit a new seal to the filler/level plug

Fit the filler/level plug and tighten to 1.75 Nm .

Fit the left-hand engine cover

Scheme 70

Position the engine cover.

Fit the three bolts in order as shown.

Tighten the bolts to 17 Nm .

Gas engine cars: Fit the front engine protector

Scheme 71

Position the engine cover.

Secure the engine protector with bolts and screws. Tighten to 10 Nm .

Fit the pulse sensor

Scheme 72

Position the sensor and fit the two bolts.

Tighten the bolts to 20 Nm .

Fit the hydraulic clutch cylinder to the gearbox

Scheme 73

Position the hydraulic clutch cylinder and pipe.

Note. Depress the piston as far as possible.

Fit the bolt to the support.

Remove the lock clip from the clutch cylinder.

Fit the two bolts.

Tighten the bolts to 30 Nm .

Insert the hose into the support and fit the lock clip.

Diesel cars: Fit the intercooler hoses

Scheme 74

Fit the two hoses and tighten the hose clips.

Fit the air filter

Scheme 75

Fit the air filter in a twisting movement and press the guide pin into the support.

Thread the two bolts and tighten to 10 Nm .

Check the hatch for the gearbox in the front wing.

Fit the inlet air hose

Scheme 76

Gas engine cars

Connect the hose and secure with two hose clips.

Connect hose (D) at the rear.

Plug in the connector (C).

Connect the crankcase ventilation hose (B).

Fit the crankcase ventilation hose by (A).

Fit the preheater hose.

Diesel cars

Fit the air hose and secure it with hose clips.

Connect the air temperature sensor.

Attach the ventilation hose (B) to the crankcase.

Fit

1. Cable to the negative battery terminal
2. Engine protection plate, tightening torque 11 Nm .
3. Diesel cars: engine protection plate on underside.

Check

1. Start the engine and check the function of the clutch.

Cylinder head/gasket, replacing

Special tools

9995454

9512666

9995670

9995451

9512050

9512767

9995452

9995718

9995719

9995450

Note. As the graphics in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the graphics is always correct.

Preparation

Remove the cable from the battery negative terminal. First read Note when disconnecting and connecting the battery lead .

Scheme 77

1. Remove the front air baffle.
2. Open the engine nipple.
3. Drain the coolant into a container.
4. Close the nipple.
5. Remove the screw that holds the inlet pipe for the coolant pump to the cylinder block.

Exhaust manifold, removing

Turbo US

Remove the exhaust manifold acc. to Exhaust manifold, replacing .

Starter motor, removing

Remove

1. lower hose to the charge-air cooler.
2. inlet pipe's support console.
3. connector for oil pressure switch.
4. plastic charge-air pipe from the turbo.
5. starter motor's screws.
6. unhook the starter motor and let hang.

Components, removing

Remove

1. the cover over the injectors
2. the cover over the throttle housing.
3. the upper timing cover
4. the cover over the ignition coils.
5. the front timing cover.
6. the throttle cable from the throttle housing's console.

Remove

1. the brake servo's vacuum hose. Pull on the hose while pressing down the plastic ring.
2. the turbo control valve from the air filter housing.
3. the mass air flow sensor's connector.
4. EVAP-valve's connection to mass air flow sensor's hose.
5. air filter housing's top part complete with hose.
6. the pipe screw for the water-heated crankcase ventilation.
7. the auxiliaries belt

Scheme 78

Remove

1. the screw from the ignition coils' ground.
2. the camshaft position sensor.

Remove

1. the ignition coils' connectors.

Place the cable harness to the side.

Screw loose the cable channel from the cylinder head's trailing edge and the throttle housing's console. Disconnect cables and hoses from the cylinder head's trailing edge.

Remove

1. water temperature sensor's connector.
2. injectors' connectors.

Lay the cable channel and cable harness to the side.

Mark up and remove ignition coils and ignition cables.

Remove

1. camshaft's rear cover.
2. the camshaft position (CMP) sensor housing
3. the trigger wheel.

Scheme 79

Remove

1. upper radiator hose with thermostat housing's cover.
2. the screw holding the dip stick pipe to the intake manifold
3. connectors from air assistance valve and throttle position sensor.
4. crankcase ventilation's hose from camshaft cover.
5. vacuum hoses from inlet pipe, mark up location.
6. console between servo pump/inlet pipe.
7. screws that hold inlet pipe to the cylinder head.
8. the intake manifold

Timing belt pulley, removing

Remove the timing belt pulley acc. to Camshaft seals, replacing .

Remove the engine mount front for cylinder head.

Scheme 80

Remove the two screws at the coolant pipe connection to the bypass channel.

Carefully turn the pipe to remove it from the cylinder block.

Scheme 81

Remove

1. VVT-valve.
2. spark plugs from cylinder 1 and 4.

Install tool 9995454 (2 pcs.) with 2-3 mm clearance to camshaft cover. Make sure that the screws in the spark plug thread is tightened all the way in.

Remove all the screws securing the camshaft cover to the cylinder head.

Scheme 82

Use pliers 9995670 to lift the cover from the cylinder head. Use the pliers at the pry lugs. Begin at cylinder and move alternately backwards.

Loosen the wing nuts a few turns and repeat the procedure.

Carefully press out the front and rear camshaft seals.

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000) .
2. the camshaft cover
3. the camshafts

Lift out the depressors. Use suction cup. Not magnet.

Scheme 83

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Scheme 84

Remove

1. the thermostat housing
2. all parts that shall be transferred to the new cylinder head.
3. gaskets.

Scheme 85

Clean the gasket faces for

1. the coolant bypass channel
2. the intake manifold
3. the cylinder block
4. camshaft cover.

When replacing/reworking of the cylinder head, clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the thermostat housing

Blow the oil ducts clean.

Installing the cylinder head

Note. For tightening torques not in the text, see Tightening torques for 4-cylinder gasoline engines .

Note. To ensure that there is no exhaust leakage, see Flanged joint, assembling .

Scheme 86

Remove the blind cover plug.

Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.

Install gauge 9995451 . Make sure that the gauge bottoms against the engine block.

Turn the crankshaft back counter-clockwise until it stops against the drift.

Check that the marking on the crankshaft timing belt pulley matches with the marking on the oil pump.

Scheme 87

Install

1. thermostat housing. Use a new gasket.
2. the manifold. Use new gaskets. Lubricate the studs using paste 116 1408

Install a new cylinder head gasket.

Install the cylinder head.

Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.

Scheme 88

Use new screws. Lubricate and install all the screws.

Tighten the screws as shown.

Tighten the screws in the following order

1. Tightening torque 20 Nm .
2. Tightening torque 60 Nm .
3. Angle tighten 130° . Use protractor «9512050»(ref-403953-S36645634772011061000000) .

Valve depressors and camshafts, installing

Note. When installing a new cylinder head, the valve clearance must be set. See Valve clearance, setting/adjusting .

Lubricate the valve guide wells.

Install all the tappets.

Note. Make sure that the depressors end up in the same place as before. If needed, replace valve depressors to achieve correct valve clearance.

Scheme 89

Lubricate the camshaft bearing seats.

Install the intake camshaft. Make sure that the groove at the back of the camshaft is above an imaginary center line.

Install the exhaust camshaft. Make sure that the groove at the back of the camshaft is below an imaginary center line.

Scheme 90

Applying liquid gasket.

Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.

Install new O-rings around the spark plug wells on the cylinder head.

Apply liquid gasket 116 1059 on the camshaft cover.

Use roller 9512767 .

The surface must be completely covered without any excess.

Camshaft cover, installing

Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.

Install all screws and tighten from the middle and out towards the edges. Tighten with 17 Nm .

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Coolant pump's inlet pipe, installing

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, 116 1056 on the screws' threads.

Scheme 91

Fit the camshaft gauge 9995452 on the rear edge of the camshafts. Make sure the screws holding the gauge to the camshafts and the screw holding the gauges together as a unit are well tightened.

Front camshaft seal, installing

Lubricate the surfaces on the seal that the camshaft rotates against.

Install the new seal for the camshaft without VVT using drift 9995719 .

Install the new seal for the camshaft with VVT using drift 9995718 .

Install the screw holding the inner timing cover to the cylinder head.

Camshafts' timing belt pulley, installing

Install the camshafts' timing belt pulley acc. to Camshaft seals, replacing .

Scheme 92

Place engine mount on cylinder head. Screw down the engine mount against the cylinder head. Tighten with 35 Nm and then tighten through an angle of 75° , one movement without interruption.

Right engine mount, installing

Install the lower timing cover.

Screw down the engine mount against the engine. Tightening torque 67 Nm .

Install

1. screws on the body's console. M10 screw tighten with 50 Nm
2. Install the upper timing cover.

Remove lifting beam and lifting hook.

Install

1. the servo reservoir.
2. servo hose's metal console on the auxiliary unit belt's rotation guard.
3. the auxiliaries belt
4. rear camshaft cover.

Installing components

Install

1. blinder. Tightening torque 17 Nm .
2. camshaft sensor housing. Tightening torque 5 Nm .
3. cable channel.

Inlet pipe, installing

Install

1. inlet pipe. Use new gasket. Tightening torque 17 Nm .
2. vacuum hoses from inlet pipe acc. to marking.
3. crankcase ventilation's hose on camshaft cover.
4. connectors from air assistance valve and throttle position sensor.
5. oil dipstick tube.
6. upper radiator hose with thermostat housing's cover.

Components, installing

Install

1. the ignition coils and ignition cables according to earlier markings.
2. the ignition coils' ground cable.
3. the camshaft position sensor.

Lay the cable channel and cable harness in place.

Install

1. the cable channel's screws on the cylinder head's trailing edge and the throttle housing's console.
2. console between inlet pipe and servo pump.
3. injectors' connectors.
4. water temperature sensor's connector.
5. air preheating hose between air filter and exhaust manifold's heat shield plate.
6. the auxiliaries belt
7. the pipe screw for the water-heated crankcase ventilation.
8. air filter housing's top part complete with hose.
9. EVAP-valve's connection to mass air flow sensor's hose.
10. the mass air flow sensor's connector.
11. the turbo control valve on the air filter housing.
12. brake servo's vacuum hose.
13. throttle cable.
14. the inlet hose between mass air flow sensor and throttle housing.
15. the front timing cover.
16. the cover over the ignition coils.
17. the upper timing cover
18. the cover over the throttle housing.
19. the cover over the injectors

Scheme 93

Press the fuel line into its quick-coupling on the fuel rail.

Exhaust manifold, installing

Turbo US

Install the exhaust manifold acc. to Exhaust manifold, replacing .

Starter motor, installing

Install

1. the blind cover plug.
2. the starter motor
3. plastic charge-air pipe to the turbo.
4. inlet pipe's support console.
5. connector for oil pressure switch.
6. lower hose to the charge-air cooler.
7. front air baffle.
8. right front wheel acc. to «Installing wheels»(ref-441449-S18457544952011121500000) .
9. the negative battery cable. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000) .

Checking performed work

Change oil and oil filter, and fill coolant.

Check

1. the engine oil level
2. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Removing turbocharged engines with the transmission

See Removing turbocharged engines with the transmission

Conditions

Remove both the screws. Move the bracket for the A/C hose to one side.

Installing the lifting beam and lifting hook

Remove the metal bracket for the servo hose from the rotation protection for the auxiliaries belt.

Position lifting beam 9995006 slightly in front of the front lifting eyelet for the engine. Use lifting arm 9995383 and lifting hook 9995460 to raise the front of the engine a few millimeters.

Removing the right-hand engine mounting

Remove

1. the screws for the servo holder
2. the engine mounting screws
3. the engine mounting.

Installing the right engine mounting

Screw the engine mounting onto the engine. Tighten to 67 Nm .

Install the screws on the bracket for the bodywork. Tighten to 50 Nm .

Remove the lifting beam and lifting hook.

Install

1. the power steering reservoir
2. the metal bracket for the servo hose.

Scheme 94

Remove

1. the air cleaner assembly. See «Removing the air cleaner (ACL) housing»(ref-441341-S08398877622012031900000)
2. the nut for the engine mounting in the bodywork.

Position lifting beam 9995006 and lifting hook 9995460 in the rear eyelet for the engine. Lift the engine until the screws can be removed.

Remove

1. the three nuts for the engine mounting on the transmission bracket
2. the engine mounting.

Installing the left-hand engine mounting

Install

1. the engine mounting. Correctly position the rubber guard
2. the nuts on the transmission bracket. Tighten to 45 Nm
3. the screw and nut. Tighten by hand.

Remove the lifting beam and lifting hook.

Tighten to 98 Nm .

Install the air cleaner. See Installing the air cleaner (ACL) housing .

Scheme 95

Remove

1. the screw and nut (B) from the engine mounting
2. the screws (A)
3. the engine mounting.

Installing the front engine mounting

Install

1. the engine mounting. Position the hole against the front of the car
2. the screws in the front-rear strut. Tighten to 35 Nm
3. the screw and the nut in the engine mounting. Tighten to 55 Nm .

Scheme 96

Remove

1. the parallel strut for the front suspension
2. the heat deflector plate
3. the screws (A) from the mounting in the car body
4. the nut and screw (B). Slowly pull the engine mounting downwards
5. the screws (C)
6. the engine mounting.

Installing the rear engine mounting

Install

1. the engine mounting with the hole pointing backwards
2. the screws (C). Tighten to 35 Nm
3. the screw and the nut (B). Tighten by hand
4. the screws (A). Tighten to 69 Nm .

Note. Ensure that the bushings are correctly positioned as shown.

Remove the screw (B) for the front engine mounting.

Tighten the rear screw first, then the front screw. Tighten to 55 Nm .

Install

1. the heat deflector plate
2. the parallel strut for the front suspension.

Replacing the air cleaner (ACL)

Note. The graphics are used for different model years and/or models. Some variation may occur. However, the essential information in the graphics always corresponds to the text.

Remove

1. the cable from the battery negative terminal. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000)
2. the cable from the battery positive terminal
3. the battery.

Scheme 97

Remove

1. the connectors from the mass air flow (MAF) sensor and the assisted air control valve. Disconnect the connectors, vacuum hoses and wiring from the air cleaner (ACL) housing
2. the assisted air control valve from the air cleaner (ACL) housing
3. the inlet hose from the terminal on the mass air flow (MAF) sensor
4. the preheating hose.

Scheme 98

Remove

1. the screws for the relay box. Move the box to one side
2. the screws for the air cleaner (ACL) housing.

Release the clip holding the fresh air intake on the air cleaner (ACL) housing. Lift off the air cleaner (ACL) housing assembly.

Scheme 99

Position the air cleaner (ACL) housing.

Install

1. the screws for the air cleaner (ACL) housing
2. the screws for the relay box
3. the preheating hose
4. the inlet hose
5. the assisted air control valve.

Reconnect the vacuum hoses, connectors and wiring.

Installing the battery

Install

1. the battery
2. the cable on the battery positive terminal
3. the cable on the battery negative terminal. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000) .

Replacing the cover on top of the engine

See Replacing the cover on top of the engine

Replacing the oil pump and front crankshaft seal

Special tools

9995433

9986187

9995919

9995455

9512050

Removing the timing belt

Remove the timing belt, see Removing the timing belt .

Scheme 100

1. Install counterhold «9995433»(ref-403953-S41906385022011061000000)
2. Counterhold and remove the crankshaft center nut
3. Work the vibration damper loose and remove by hand
4. Remove the timing belt.

Scheme 101

1. Use universal puller «9986187»(ref-403953-S19032335482011061000000) and two of the vibration damper screws
2. Tighten both the screws by hand to stop in the pulley
3. Install the puller so that the claws engage in the screws, not in the camshaft pulley. NOTE: Ensure that the tool claws do not damage the pulley teeth.

Scheme 102

1. Remove the old seal using a groove-cut chisel or: «9995919»(ref-403953-S08553537872011061000000)
2. Clean the mating surface
3. Grease and install a new seal. Use tool «9995455»(ref-403953-S11536463532011061000000)
4. Press in the seal using a drift and the crankshaft center nut as shown. NOTE: Ensure that the crankshaft does not rotate when pressing in the crankshaft seal.

Scheme 103

1. Remove the four oil pump screws
2. Remove the oil pump. Use a groove-cut chisel and carefully break at the stop lugs
3. Clean the gasket face and the mating surfaces.

Scheme 104

Install the new oil pump.

1. Install a new gasket
2. Carefully insert the oil pump over the end of the crankshaft. NOTE: Do not damage the sealing ring in the oil pump during installation.
3. Install 4 new screws as guides
4. Pull in the oil pump with drift «9995455»(ref-403953-S11536463532011061000000) and the crankshaft center nut. NOTE: Ensure that the crankshaft does not rotate when drawing in the pump.
5. Tighten the screws crosswise. Tighten to 10 Nm
6. Install the crankshaft timing gear pulley. Carefully tap alternately around the pulley until end position is reached. NOTE: The timing gear pulley can only be in one position on the splines on the end of the crankshaft.

Installing the timing belt

Install the timing belt according to Installing the timing belt .

Replacing the timing belt

Special tools

9995006

9995383

9995460

Scheme 105

1. Turbocharged engines: remove the right hand engine cover and the cover over the right headlamp.
2. Slacken off the auxiliaries belt by turning the screw on the tension pulley clockwise
3. Remove the auxiliaries belt.

Removing the timing covers

Remove

1. the upper timing cover
2. the front timing cover.

Remove the metal bracket for the servo hose from the rotation protection for the auxiliaries belt.

Position lifting beam 9995006 slightly in front of the front lifting eyelet for the engine. Use lifting arm 9995383 and lifting hook 9995460 to raise the front of the engine a few millimeters.

1. the screws for the servo holder
2. the engine mounting screws
3. the engine mounting
4. the lower timing cover.

Scheme 106

Remove the right front wheel.

Position the upper timing cover.

Turn the crankshaft until the markings on the crankshaft and camshaft pulley correspond.

Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The markings are shown. Remove the upper timing cover.

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw still. Turn the tensioner eccentric clockwise using a 6 mm Allen key to 10 o'clock.

Remove the timing belt from the tension pulley, camshaft pulley and water pump.

Tensioning the tensioner pulley and the idler pulley

Spin the idler pulley and listen for noise. When replacing with a new idler pulley, tighten to 24 Nm .

Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw.

Screw in the center screw by hand.

Ensure that the tensioner fork is centered over the cylinder block rib.

Ensure that the Allen hole on the eccentric is at "10 o'clock".

Scheme 107

Remove

1. the front air baffle
2. the rear air baffle.

Scheme 108

Remove

1. the two screws from the lower belt cover
2. the lower belt guard
3. the timing belt using a twisting movement
4. clean the surrounding area.

Install the timing belt over the pulley on the crankshaft.

Install

1. the lower belt guard
2. the front air baffle
3. the rear air baffle.

Install the new belt in the following order

1. crankshaft
2. the idler pulley
3. intake camshaft
4. exhaust camshaft
5. water pump
6. belt tensioner.

Tension the timing belt

Note. This adjustment is to be made with a cold engine. Suitable temperature is approximately 20°C/67°F. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The graphic shows the position of the indicator at different engine temperatures.

1. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
2. Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window
3. Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm .

Check that the indicator is in the correct position.

Scheme 109

1. Press the belt to check that the indicator on the tensioner moves easily
2. Install the upper timing cover
3. Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond. NOTE: Check that the indicator on the belt tensioner is within the marked area.

Installing timing covers

Install

1. the lower timing cover
2. the front timing cover. Tighten to 12 Nm
3. the auxiliaries belt.

Screw the engine mounting into place on the engine. Tighten to 67 Nm .

Install

1. the screws on the bracket for the bodywork. Tighten to 50 Nm
2. the servo reservoir.

Remove the lifting beam and lifting hook.

Install

1. the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt
2. the front wheel according to «Installing the wheels»(ref-441320-S30181955472011121500000)
3. the auxiliaries belt
4. turbocharged engines: the right hand engine cover and the cover over the right headlamp unit.

Function test

1. Test drive the engine.

VVT-unit, replacing/adjusting

See VVT-unit, replacing/adjusting

Engine components exhaust side, transferring

Note. To ensure that there is no exhaust leakage, see Flanged joint, assembling .

Scheme 110

1. The pre-heater plate
2. Exhaust manifold
3. The engine mounting on the timing belt side
4. The thermostat housing and the oil cooler and hoses
5. The bracket for the drive shaft bearing
6. The coolant pipe.

Scheme 111

1. Oil pressure sensor
2. Oil dipstick and pipe
3. Generator (GEN)
4. The intake manifold assembly with the radiator hose connection
5. The thermostat assembly
6. Knock sensor (KS)
7. The flame trap and hoses
8. The engine mountings and the lifting eyelet
9. The starter motor wiring.

Carrier plate, installing

See Install flange plate .

Scheme 112

The torque converter. Tighten to 50 Nm .

Plug the old engine in the same way as the new engine.

Install the exhaust side cover plate.

Install the speed sensor. Tighten to 20 Nm .

Install the cable mounting. Tighten the cable mounting.

1. Install the starter motor. Tighten the screws. Tighten to 50 Nm
2. Install the bracket. Finger-tighten the bracket to the intake manifold
3. Connect the wiring
4. Install the protective cover.

Special tools

9992810

9995185

9995462

9995474

9995488

9995533

9995642

9995666

Removing the left-hand side drive shaft nut

Remove the hub cap. Remove the nut.

Remove the air conditioning (A/C) hose from the fan shroud.

Scheme 113

Scheme 114

Remove

1. the heat deflector plate
2. the nuts for the engine pads
3. the front and rear screws
4. the two screws from the engine pads. Lift the front-rear member down from the car.

Scheme 115

1. Remove the nuts
2. Pull the front exhaust pipe downwards
3. Remove the gasket.

Scheme 116

Remove the four screws. Remove the engine bracket.

Scheme 117

Remove the clamps from the charge air cooler (CAC) hose.

Remove the three screws and the engine mounting.

Removing the poly V-belts

1. Relieve the load on the belts by turning the belt tensioner counter-clockwise
2. Remove the poly V-belts. Move it upwards.

Scheme 118

Unscrew the upper screw from the mounting for the power steering pump.

Remove

1. the connector (A)
2. the four mounting screws
3. the compressor. Turn the compressor upwards as far as possible
4. Move the mounting to one side.

Tie the front edge of the compressor to the car body.

Note. Do not damage the A/C hoses and pipes.

Scheme 119

Remove

1. the connector from the oil pressure sensor
2. the cable clamp from the bracket
3. the connector in the middle.

Scheme 120

Remove

1. The drive shaft bearing cap on the engine side
2. Both the front wheels
3. The brake hose clips. Lift out the hoses from their mountings
4. The ABS lines from its mountings
5. The two nuts and the upper screw from the spring strut
6. The wheel spindle from the spring strut (turn it)
7. The drive shaft from the transmission
8. The lower screw. Move the drive shaft to one side.

Insert special tool 9995488 into the transmission.

Secure the wheel spindle using the lower spring strut screw.

Tie the drive shaft to the wheel arm.

Removing the left-hand side cover

Remove the screws. Lift off the cover.

Scheme 121

Remove

1. The brake hose clips. Lift out the hoses from their mountings
2. The ABS lines from its mountings
3. The center nut from the drive shaft
4. The two nuts and the upper screw from the spring strut
5. Detach the drive shaft from the transmission. Use special tool «9995462»(ref-403953-S38748499762011061000000)
6. The drive shaft assembly
7. Insert special tool «9995488»(ref-403953-S20362794202011061000000) into the transmission
8. Secure the wheel spindle using the lower spring strut screw.

Scheme 122

Disconnect the oil pipe terminals from the transmission. Move the pipes to one side.

Ensure that no dirt gets into the transmission and hoses.

Seal all openings using plastic plugs.

Note. Do not remove the hoses from the pipes.

Removing the air cleaner (ACL)

Remove the air cleaner (ACL). See Removing the air cleaner (ACL) housing .

Scheme 123

Disconnect the connector (A).

Remove

1. The nut and the battery positive lead
2. The ground lead from the transmission.

Scheme 124

Automatic transmission

Remove: the gear selector cable mountings.

Disconnect the connector.

Remove the gear selector cable from the gear selector bevel arm on the transmission.

Remove the connectors from the transmission

1. Remove the gear selector cable from the transmission
2. The ground lead from the transmission
3. Remove the bracket for the connector from the transmission
4. Separate the connector.

Scheme 125

Scheme 126

Remove

1. The charge air pipe between the throttle body (TB) and the charge air cooler (CAC)
2. The hose for the idle air control (IAC) valve at the charge air cooler (CAC)
3. The hose at the pipe
4. The screw for the bracket. Remove the pipe assembly together with the hose.

Scheme 127

Remove

1. the cover by removing one screw and two plugs
2. the cable with the throttle in the wide open position
3. the retaining clip. Remove the cable sleeve.

Scheme 128

Remove the connectors for

1. the engine speed (RPM) sensor
2. the camshaft position (CMP) sensor
3. the knock sensor (KS)
4. the cable harness.

Remove

1. the protective tube from the 3 clips
2. the brake servo hose from the power brake booster (press in the snap-ring and pull out the hose)
3. the hose from the valve for the air cleaner (ACL).

Removing the fuel line from the engine

1. Press the lock facing together. Pull out the fuel line
2. Disconnect the pipe from the clamps. Move the pipe to one side.

Scheme 129

Disconnect the connectors from the engine.

Note. Note the position of all the mounting points for the cable harness.

Remove

1. the engine coolant temperature (ECT) sensor
2. the cable from the bracket
3. the cover over the injectors (pull the cover off)
4. the injectors
5. the throttle position (TP) sensor
6. idle air control (IAC) valve
7. the cable guide by slackening off one screw and a nut
8. the switch for the tail lamp
9. move the entire cable harness to one side.

Scheme 130

Remove

1. the clamps
2. the upper radiator hose
3. the lower radiator hose on the engine side.

Scheme 131

Remove

1. slacken off the hose clamps (make a note of how the hoses are routed)
2. pull off the heater hoses.

Scheme 132

1. Remove the brackets between the power steering pump and the intake manifold and the lower bracket
2. Remove the Poly V-belt
3. Remove the mounting screws between the spokes on the pulley
4. Remove the oil reservoir from the bodywork. Release the hose from the clips
5. Remove the power steering pump. Place the pump to one side.

Scheme 133

Remove the two screws.

Remove the support on the body side.

Support the hood.

Scheme 134

Hang lifting hooks 9995185 and 9995642 on 9992810 .

Raise the lifting equipment until it takes the strain off the engine.

Remove the engine mounting on the transmission side

1. Remove the nut and the screw
2. Remove the three screws. Remove the transmission bracket.

Remove the engine mounting from the upper timing belt cover.

Note. Check carefully that the driveline is clear of the bodywork and other optional equipment. Turn the clamp at the oil cooler if necessary.

Lift out the engine.

Adjust the lifting equipment continuously throughout the lift.

Return the hood to the normal position.

Replacing camshaft seal (retaining ring) front side

Special tools

9995719

9995718

9995919

Install camshaft retaining ring

1. Grease the new retaining ring
2. Install the ring by using special tool «9995718»(ref-403953-S24775656662011061000000) at VVT side and «9995719»(ref-403953-S10206011822011061000000) at other side.
3. Remove the tools and check proper fitting.

1. Install gear pulley, see «Installing the camshaft timing gear pulley»(ref-441341-S18199596932011121500000) .
2. Install toothed belt, see «Install auxiliaries belt»(ref-441341-S01401045242011121500000) .

Check for leakage.

Replacing engine mounting bolsters

Special tools

9995006

9995383

9995460

Prerequisites

1. Remove the right engine bay cover
2. Remove the two bolts and move the AC hose support to one side.

Scheme 135

Remove the engine bolster nut.

Position the lifting beam 9995006 and the support 9995383 over the engine and locate the lifting lug 9995460 at the front lifting eye.

Lift the engine up until the engine bolster bolt can be removed.

Remove the three bolts and remove the support (pushing power steering hose to one side).

Install the support on the engine and tighten the bolts. Torque setting 76 Nm .

Install the engine bolster. Finger-tighten.

Remove the lifting beam.

Tighten the bolster nut. Torque setting 98 Nm .

Install the hose support. Torque setting 10 Nm .

Install the engine cover.

Install the right engine bay cover.

Replacing engine mounting bolster at transmission side

Remove the complete air cleaner (ACL), see Removing the air cleaner (ACL) housing .

Remove the engine bolster nut.

Lift the engine/transmission up until the engine bolster bolt can be removed.

When lifting the engine/transmission, use a block of wood to protect the transmission.

Remove the cable harness clip from the wire end.

Remove the three nuts and remove the mounting bolster.

Install the mounting bolster and place the 2 rubber protecting flaps in the correct position.

Install the 3 nuts. Torque setting 45 Nm .

Install the bolt and the nut in the bolster. Finger-tighten.

Remove the lifting beam.

Tighten the bolster nut. Torque setting 98 Nm .

Install the complete air cleaner (ACL), see Installing the air cleaner (ACL) housing .

Install the inlet air-preheater hose.

Replacing flange plate

Special tools

9995112

Scheme 136

Use gear selector 9995112 to block the flange plate.

Remove the bolts and take the flange plate off.

Install flange plate

Clean the surfaces from flange plate and crankshaft fixation.

Fit the bolts finger tighten.

Tighten the bolts to in two stages diagonally.

Stage 1: 45 Nm .

Stage 2: angle tighten 45° turn.

Replacing rearmost crankshaft retaining ring

Special tools

9991801

9995112

9995676

Note. This method assumes the transmission has been removed.

Removing flange plate

See Remove flange plate .

Scheme 137

Remove the retaining ring with a screwdriver.

Note. Do not damage the contact faces. Note the position of the retaining ring relative to the retaining ring holder.

Oil the retaining ring mating lips.

Install the retaining ring using the installation kit 9995676 and the universal handgrip 9991801 .

Tap the retaining ring in until the die touches the crankshaft.

Installing flange plate

See Install flange plate .

Replacing the camshaft seals

Special tools

9995006

9995383

9995460

9995452

9995451

9995199

9995718

9995719

9995651

Note. The crankshaft and the camshafts must not be turned more than is stated in the method description. If the shafts are turned in any other way the valves may be damaged.

Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Remove

1. the cable from the battery negative terminal. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000)
2. the inlet hose between the air cleaner (ACL) and throttle body (TB). Place it to one side.

Remove

1. the brake servo vacuum hose from the terminal in the throttle body (TB). Disconnect the hose by pressing the plastic ring down. At the same time pull the hose upwards. Move the hose to one side
2. the fuel line and wiring from the clips at the rear edge of the cylinder head.

Remove

1. the screws for the cable duct
2. the rear cover for the camshaft
3. the camshaft position (CMP) sensor housing
4. the trigger wheel
5. the right-hand engine splash guard
6. the auxiliaries belt.

Remove

1. the upper timing cover
2. the front timing cover.

Remove the nut for the engine mounting.

Remove the metal bracket for the servo hose from the rotation protection for the auxiliaries belt.

Position lifting beam 9995006 slightly in front of the front lifting eyelet for the engine. Use lift arm 9995383 and lifting hook 9995460 to lift the front edge of the engine a few mm until the engine mounting screw can be taken out.

Scheme 138

Remove

1. the screws for the servo holder
2. the engine mounting screws
3. the engine mounting.

Position the engine according to the marking

Remove the right front wheel.

Position the upper timing cover.

Turn the crankshaft until the markings on the crankshaft and camshaft pulley correspond.

Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The markings are shown. Remove the upper timing cover.

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw still and turn the tensioner eccentric clockwise to the "10 o'clock" position using a 6 mm Allen key.

Remove the timing belt from the camshaft pulleys.

Removing the timing gear pulley

Timing gear pulleys with variable valve timing unit

1. Install camshaft adjustment tool «9995452»(ref-403953-S02369714572011061000000) at the rear of the camshafts.

Timing gear pulleys with variable valve timing units

1. Remove the plug at the front edge of the variable valve timing unit (TORX 55)
2. Remove the center screw from the VVT unit (TORX 55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit. A small amount of oil may run out. Place paper underneath.

Timing gear pulleys without variable valve timing units

1. Remove the screws for the timing gear pulley. Use counterhold «9995199»(ref-403953-S15123702502011061000000)
2. Remove the timing gear pulley
3. Remove tool «9995452»(ref-403953-S02369714572011061000000)
4. Remove the screw holding the inner timing cover to the cylinder head.

Replacing the camshaft seal

Carefully press in tool 9995651 between the sealing ring and the camshaft.

Carefully pry out the seal.

Oil the new seal.

Scheme 139

Install the new seal for the camshaft with variable valve timing. Use drift 9995718 .

Install the new seal for the camshaft without variable valve timing. Use drift 9995719 .

Install the screw holding the inner timing cover to the cylinder head.

Remove

1. the front air baffle
2. the support between the cylinder block and the intake manifold
3. the mounting screws for the starter motor
4. the lower timing cover.

Place the starter motor to one side.

Remove the blind cover plug and the blind cover washer

Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.

Install adjustment tool 9995451 . Ensure that the adjustment tool bottoms out against the cylinder block.

Turn the crankshaft back counter-clockwise until it stops against the drift.

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Installing the camshaft timing gear pulley

Timing gear pulleys without variable valve timing (VVT)

1. install the upper timing cover
2. install the timing gear pulley without variable valve timing on the camshaft. Use the two screws positioned so that the markings on the timing gear pulleys and upper timing cover correspond. Do not tighten.

Timing gear pulleys with variable valve timing (VVT)

1. Install the timing gear pulley using the center screw on the camshaft. Ensure that the markings on the timing gear pulleys/upper timing cover correspond. Do not tighten.

Install the timing belt on the timing gear pulleys.

Note. Adjust so that the screws in the timing gear pulley without variable valve timing do not reach the limit position in the oval holes.

Note. This adjustment is to be made with a cold engine. Suitable temperature is approximately 20°C/67°F. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The graphic shows the position of the indicator at different engine temperatures.

1. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft.
2. Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
3. Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm .

Check

1. Press the belt to check that the indicator on the tensioner moves easily
2. Install the upper timing cover
3. Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond. NOTE: Check that the indicator on the belt tensioner is within the marked area.
4. Remove the upper timing cover.

Install

1. the lower timing cover
2. the front timing cover. Tighten to 12 Nm
3. the upper timing cover.

Screw the engine mounting onto the engine. Tighten to 67 Nm .

Install the engine mounting screw and nut in the bodywork bracket. Tighten by hand.

Remove the lifting beam and lifting hook.

Tighten the engine mounting nut. Tighten to 98 Nm .

Install

1. the power steering reservoir
2. the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt
3. the auxiliaries belt
4. the rear camshaft cover
5. the trigger wheel. Tighten to 17 Nm
6. the camshaft position (CMP) sensor housing. Tighten to 5 Nm
7. the cable duct
8. the brake servo vacuum hose
9. the hose between the intake manifold and air cleaner (ACL) housing
10. the blind cover plug
11. the mounting screws for the starter motor
12. the support between the cylinder block and the intake manifold
13. the front air baffle
14. the cable from the battery negative terminal. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000) .

Function test

1. Test drive the car.

Special tools

9995702

Scheme 140

1. Remove the screws from the rear of the cover
2. Remove the two screws from the timing gear side
3. Undo the clips on the timing gear side. Remove the cover(s).

Installing the cover on top of the engine

1. Position the cover(s)
2. Secure the clips on the timing gear side
3. Install the screws. Tighten to 10 Nm .

Replacing the cylinder head and gasket

Special tools

9995454

9512666

9995670

9995451

9512050

9512767

9995452

9995718

9995719

Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Disconnect the battery negative lead. First read Note when disconnecting and connecting the battery lead .

Separating the exhaust system

Remove the nuts where the three-way catalytic converter (TWC) and the front exhaust pipe divide.

Unhook the exhaust system and allow it to hang.

Removing the manifold and turbocharger (TC)

Remove the manifold. See Exhaust manifold, replacing .

Removing the starter motor

Remove

1. the lower hose for the charge air cooler (CAC)
2. the support bracket for the intake manifold
3. the connector for the oil pressure switch
4. the plastic charge air pipe from the turbocharger (TC)
5. the screws for the starter motor
6. unhook the starter motor and allow it to hang.

Removing the fuel line

Disconnect the quick-release connector between the fuel line and the fuel rail.

Use tool 9512666 .

Removing components

Remove

1. the cover over the injector
2. the cover over the throttle body (TB)
3. the upper timing cover
4. the cover over the ignition coils
5. the front timing cover
6. the throttle cable from the bracket for the throttle body (TB).

Remove

1. the vacuum hose for the brake servo. Pull the hose while pressing the plastic ring down
2. the turbocharger (TC) control valve from the air cleaner (ACL) housing
3. the connector for the mass air flow (MAF) sensor
4. the EVAP hose connection to the mass air flow (MAF) sensor hose
5. the upper section of the air cleaner (ACL) housing and hose
6. the pipe screw for the water-heated crankcase ventilation
7. the auxiliaries belt.

Removing the intake manifold

Remove

1. the upper radiator hose together with the cover for the thermostat housing
2. the screw holding the dip stick pipe to the intake manifold
3. the connectors from the assisted air control valve and the throttle position (TP) sensor
4. the hose for the crankcase ventilation from the camshaft cover
5. the vacuum hoses from the intake manifold, mark up the position
6. the bracket between the servo pump and intake manifold
7. the screws holding the intake manifold to the cylinder head
8. the intake manifold.

Install the lifting beam and the lifting hook. See Installing the lifting beam and lifting hook .

Remove the right engine mounting. See Removing the right-hand engine mounting .

See Position the engine according to the marking .

Remove the timing belt according to Removing the timing belt .

Remove the timing gear pulley. See Removing the timing gear pulley .

Releasing the intake pipe for the coolant pump

Remove the two screws at the coolant pipe connection to the bypass channel.

Carefully turn the pipe to remove it from the cylinder block.

Removing the camshaft cover and cylinder head

Remove

1. the variable valve timing valve
2. the spark plugs from cylinders 1 and 4.

Install 2 tools 9995454 . Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened.

Remove all the screws securing the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head. Install the pliers at the stop lugs. Start at the cylinder and work alternately backward.

Slacken off the wing nuts a few turns. Repeat the procedure.

Carefully press out the front and rear camshaft seals.

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000)
2. the camshaft cover
3. the camshafts.

Lift out the valve lifters. Use suction pads. Do not use magnets.

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Scheme 141

Remove

1. the thermostat housing
2. the heat deflector plate above the manifold
3. the manifold and gaskets.

Cleaning the gasket face

Clean the gasket faces for

1. the coolant bypass channel
2. the intake manifold
3. the cylinder block
4. camshaft cover.

When replacing or machining the cylinder head, clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. thermostat housing.

Blow the oil ducts clean.

Note. For tightening torques not in the text, see Tightening torques for 4-cylinder gasoline engines .

Aligning the crankshaft

Remove the blind cover plug.

Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.

Install adjustment tool 9995451 . Ensure that the adjustment tool bottoms out against the cylinder block.

Turn the crankshaft back counter-clockwise until it stops against the drift.

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

When replacing or working on the cylinder head

Install

1. the thermostat housing. Use a new gasket
2. the manifold. Use new gaskets. Lubricate the studs with paste 1161408
3. the heat deflector plate above the manifold.

Install a new cylinder head gasket.

Install the cylinder head.

Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.

Scheme 142

Use new screws. Lubricate and install all the screws.

Tighten the screws as shown.

Tighten the screws in the following order

1. Tighten to 20 Nm
2. Tighten to 60 Nm
3. Angle-tighten 130°. Use protractor «9512050»(ref-403953-S36645634772011061000000) .

Installing the valve lifters and camshafts

Note. When installing a new cylinder head, the valve clearance must be set. See Valve clearance, setting/adjusting .

Lubricate the valve guide wells.

Install all the valve lifters.

Note. Make sure that the lifters are in the same position as before.

Lubricate the camshaft bearing seats.

Install the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.

Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.

Applying liquid gasket.

Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.

Install new O-rings around the spark plug wells on the cylinder head.

Apply liquid gasket 116 1059 to the camshaft cover.

Use roller 9512767 .

The surface must be completely covered without any excess.

Installing the camshaft cover

Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters.

Install the camshaft cover.

Install 2 press tools 9995454 .

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.

Install the intake manifold and lifting eyes, tighten screws from the middle and outwards.

Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket.
2. the spark plugs. Tighten to 30 Nm .

Installing the intake pipe for the coolant pump

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant 116 156 to the screw threads.

Install camshaft adjustment tool 9995452 at the rear of the camshafts. Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Installing the front camshaft seal

Lubricate the surfaces of the seal that the camshaft rotates against.

Install the new seal for the camshaft with variable valve timing. Use drift 9995718 .

Install the new seal for the camshaft without variable valve timing. Use drift 9995719 .

Install the screw holding the inner timing cover to the cylinder head.

Install the camshaft timing gear pulley. See Installing camshafts' timing gear pulleys .

Install the timing belt. See Installing the timing belt .

Screw the engine mounting onto the engine. Tighten to 67 Nm .

Install the engine mounting screw and nut in the bodywork bracket. Tighten by hand.

Remove the lifting beam and lifting hook.

Tighten the engine mounting nut. Tighten to 98 Nm .

Install

1. the power steering reservoir
2. the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt
3. the auxiliaries belt
4. the rear camshaft cover
5. the trigger wheel. Tighten to 17 Nm
6. the camshaft position (CMP) sensor housing. Tighten to 5 Nm
7. the cable duct.

Installing the intake manifold

Remove

1. the intake manifold. Use a new gasket. Tighten to 17 Nm
2. the vacuum hoses from the intake manifold according to the markings
3. the hose for the crankcase ventilation from the camshaft cover
4. the connectors from the assisted air control valve and the throttle position (TP) sensor
5. the dip stick pipe
6. the upper radiator hose together with the thermostat housing cover.

Install

1. the ignition coils and ignition cables according to earlier markings
2. the connectors on the variable valve timing valve and ignition coils
3. the ground lead for the ignition coils
4. the camshaft position (CMP) sensor.

Place the cable duct and cable harness in position.

Install

1. the screws for the cable duct on the rear edge of the cylinder head and throttle body (TB) bracket.
2. the bracket between the intake manifold and the power steering pump
3. the connectors for the injectors
4. the connector for the engine coolant temperature sensor
5. the air preheating hose between the air cleaner (ACL) and the heat deflector plate for the exhaust manifold
6. the auxiliaries belt
7. the pipe screw for the water-heated crankcase ventilation
8. the upper section of the air cleaner (ACL) housing and hose
9. the EVAP hose connection to the mass air flow (MAF) sensor hose
10. the connector for the mass air flow (MAF) sensor
11. the turbocharger (TC) control valve on the air cleaner (ACL) housing
12. the brake servo vacuum hose
13. the throttle cable
14. the inlet hose between the mass air flow (MAF) sensor and throttle body (TB)
15. the front timing cover
16. the cover over the ignition coils
17. the upper timing cover
18. the cover over the throttle body (TB)
19. the cover over the injectors.

Installing the fuel line

Press the fuel line into the quick-release connector on the fuel rail.

Installing the exhaust manifold

Install the manifold and turbocharger (TC) according to Exhaust manifold, replacing .

Scheme 143

Install a new gasket where the front exhaust system and three-way catalytic converter (TWC) separate.

Lift up and align the front exhaust system against the manifold.

Install a new gasket and new nuts. Tighten.

Installing the starter motor

Install

1. the blind cover plug
2. the starter motor
3. the plastic charge air pipe for the turbocharger (TC)
4. the support bracket for the intake manifold
5. the connector for the oil pressure switch
6. the lower hose for the charge air cooler (CAC)
7. the front air baffle
8. the right front wheel. See «Installing the wheels»(ref-441320-S30181955472011121500000)
9. the cable to the battery negative terminal. First read «Note when disconnecting and connecting the battery lead»(ref-441395-S22382000022011121500000) .

Change the oil. Replace the oil filter. Top up the coolant.

Check

1. the engine oil level
2. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Replacing toothed (timing) belt

Special tools

9512661

9995433

9995006

9995383

9995460

Note. Service interval for timing belt and tensioner pulley: 165,000 km/105,000 miles .

Align timing gear and crankshaft according to the markings

Place the upper cover in position.

Turn the crankshaft clockwise until the markings, camshaft gear, inner timing gear cover and the crankshaft/gear wheel align with the oil pump housing.

Remove upper rear timing cover.

Scheme 144

1. Remove bolt (A) and take tensioner off
2. Remove timing belt and move it downwards
3. Clean and check the gears.

Scheme 145

Rotate the pulley rapidly and listen for abnormal noise from the bearing.

When replacing: torque setting idler pulley 25 Nm .

Check that all pulley contact surfaces for the belt are clean and smooth.

Install timing belt at lower side

Place the timing belt between damper and engine block.

Route belt upwards.

Install cover plates

1. Place the lower snow cover and fit the two bolts
2. Place the front and rear engine splashguards.

Scheme 146

1. Check timing marks
2. Position the new tensioner, and finger tighten bolt (A)
3. Turn excenter from tensioner in lowest position as shown.
4. Route the belt around the crankshaft (1) and the idler pulley (2)
5. Route the belt over both timing gears (3.4)
6. Route the belt over the water pump (5) and around the tension pulley (6)
7. Install upper rear timing cover on engine (do not tighten)
8. Check alignment.

Scheme 147

1. Tighten bolt (B) to 3 Nm
2. Place a 6 mm hex tool in the tensioner and turn tensioner anti clockwise until the toothed belt is tensioned .
3. Move the adjuster until the indicator pin is in the middle (A)
4. Tighten the bolt (B) to 20 Nm without moving the tensioner.
5. Re-adjust if necessary.
6. Press pin (A) clockwise and anti-clockwise to check.

Check timing belt tension

1. Rotate the crankshaft two revolutions and check that the markings on the crankshaft pulley and timing gears align with the marks on the timing gear cover.
2. Check the adjustment of the tensioner (indicator pin (A) in the middle)
3. Adjust again if necessary, see «Adjusting timing belt tension»(ref-441341-S10641134712011121500000) NOTE: After adjustment always turn crankshaft twice.
4. Remove upper timing cover.

Install engine bracket

Clean mounting pin, position bracket and install bolts. Tightening torque 35 Nm + 75° .

Install timing gear covers

Install

1. lower timing gear cover. Check lower cover and water hose fittings.
2. the top cover (1x screw) (B), torque setting 10 Nm
3. the top timing cover and tighten. NOTE: Close lid in side cover move front wheels straight.

Install auxiliaries belt

1. Clean the pulley grooves
2. Turn the tensioning device clockwise
3. Install the auxiliaries belt as shown.
4. Release the belt tensioner (counterclockwise)
5. Tighten the bracket. Torque to 10 Nm
6. Install power steering hose. Torque 10 Nm .

Scheme 148

1. Position the support on the engine and tighten the bolts (A) to 67 Nm
2. Loosely install the bolts in the body support.
3. Remove the lifting beam «9995006»(ref-403953-S21073303002011061000000)
4. Tighten the body support (B) nut to 98 Nm .

Test drive engine

Start the engine and check function.

1. Install the right engine compartment cover and headlight unit cover.

Place the hood in the service position

See Place hood in service position .

Automatic transmission: Installing the gear selector mechanism cables

Check the gear selector mechanism cables.

Install

1. The connectors and the mounting
2. Ground lead
3. Gear selector cables.

Scheme 149

1. Install the mounting on the transmission. Tighten to 45 Nm .

Note. Ensure that the rubber protectors are correctly positioned.

1. Install the screw and the nut on the engine mounting in the body
2. Remove the lifting equipment
3. Tighten the screws for the engine mountings on the left and right-hand sides. Tighten to 98 Nm .

Return the hood to the normal position.

Scheme 150

Connect

1. The injectors. Secure the wiring
2. The wiring for the ignition coil and the ground lead
3. The cable mounting on the engine. Tighten the mounting. Tighten to 10 Nm
4. The positive crankcase ventilation (PCV) valve.
5. The throttle position (TP) sensor and the idle air control (IAC) valve.

Fuel hose, routing and connecting

Connect the fuel hose(s). Pull the hose(s) to check that they are secure.

Charge air hose from the turbocharger (TC), upper hose, installing

1. Install the pipe and insert in the upper hose.
2. Install the clamp. Connect to the engine via the intermediate pipe. Tighten the hose clamps.

Scheme 151

Install the air conditioning (A/C) compressor. Install the bracket on screw (B). Do not tighten the screw (B). Tighten the other screws. Tighten to 25 Nm .

Scheme 152

Connect the connectors for

1. Generator (GEN)
2. The sensor on the A/C compressor
3. The oil pressure sensor.

Scheme 153

Remove special tool 9995488 from the transmission.

Install the drive shaft in the transmission and the bearing.

Finger tighten the bearing cap.

Secure the wheel spindle on the spring strut. Install the screws and nuts.

Tighten the bearing cap screws. Tighten to 25 Nm .

Engine mounting rear, installing

Install the mounting. Tighten the 4 screws.

Tighten to 40 Nm .

Scheme 154

Connect the inlet hose to the charge air cooler (CAC). Tighten the hose.

Secure the hose on the engine mounting. Tighten on the engine with three screws. Tighten to 50 Nm .

Tighten the nut for the clamp.

Tighten to 6 Nm .

Install the air conditioning (A/C) pipe in the engine mounting.

Front-rear member, installing

Install heat shield.

Install the front-rear member. Insert the two screws (B) through the engine pads. Tighten the two screws.

Install the front and rear engine screws (A). Tighten the screws. Tighten to 69 Nm .

Note. Position the rubber elements in the correct positions as shown. The position of the mounting points for the front-rear member must be the same at both the front and the rear.

Slacken off the screw (B) for the front engine pad. First tighten the screw for the rear engine pad. (Tighten to 55 Nm .) Then tighten the screw for the front engine pad. (Tighten to 55 Nm .).

Scheme 155

Install a new gasket.

Tighten the nuts. Tighten to 25 Nm .

Automatic transmission: Installing the oil pipes

Install the lower pipe. Use a new O-ring.

Install the upper pipe (the return line) with the mounting in the control system cover. Install the connection loosely.

The pipe cap nut is tightened later.

Scheme 156

1. Clean the drive shaft and the splines
2. Remove special tool «9995488»(ref-403953-S20362794202011061000000) from the transmission
3. Remove the screw from the wheel spindle/spring strut.
4. Insert the drive shaft into the transmission. Press the drive shaft in as far as it will go.
5. Position the hub over the drive shaft splines. Install the nut.
6. Install the two screws on the wheel spindle/spring strut.

Lateral strut, installing

1. Install the lateral strut. Use screws
2. Tighten the screws. Tighten to 50 Nm .

Scheme 157

Install

1. Tighten the two screws on the wheel spindle/spring strut. Tighten to 90 Nm
2. Secure the ABS lines in their mountings
3. Install the brake hose in the mounting. Secure using a clamp.

Front wheel, installing

1. Install the wheels. Tighten the nuts slightly
2. Then tighten crosswise. Tighten to 110 Nm .
3. Torque tighten the wheel nuts one more time.
4. Lower the car.

Note. When tightening using a pneumatic impact wrench, only use torque socket 9512834 .

Note. Tightening crosswise to the correct torque is important to prevent stresses in the brake disc.

Tighten the center nut (A). Tighten to 120 Nm + 60° .

Air cleaner (ACL), installing

See Installing the air cleaner (ACL) housing .

Battery, installing

1. Install the battery shelf. Tighten to 16 Nm
2. Install and secure the battery with the clamp. NOTE: Cars with cruise control: The vacuum hose and vacuum motor wiring must be connected before the battery shelf is screwed into place.

Scheme 158

1. Clean the air intake hose and the throttle body (TB)
2. Install the hose. Tighten the clamp NOTE: Ensure that the clamp never comes into contact with the throttle pulley in the idling or wide open throttle (WOT) positions.
3. Connect the idle hose to the idle air control (IAC) valve. Use a new hose clamp.

Scheme 159

1. Install the power steering pump and the screws.
2. Loosely install the support bracket between the generator (GEN) and the intake manifold. Install the lower bracket.
3. Tighten the screws. Tighten to 25 Nm .
4. Secure the cable in the bracket.
5. Tighten the support bracket between the generator (GEN) and the intake manifold. Tighten to 25 Nm .
6. Tighten the lower screw on the support bracket. Tighten to 25 Nm .

Poly V-belts, installing

1. Clean the belt pulley track
2. Turn the belt tensioner unit clockwise
3. Install the auxiliaries belt as shown.
4. Release the belt tensioner equipment (counter-clockwise)
5. Tighten the bracket. Tighten to 10 Nm
6. Install the power steering hose. Tighten to 10 Nm .

Coolant, filling

See Filling with coolant

Install all covers.

Check the oil level in the automatic transmission. See Checking Oil Level .

Special tools

9995452

9995199

Note. Since the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Note. Crankshaft and camshafts must not be turned more than is stated in the method description. If the shafts are turned in any other way the valves may be damaged.

Prepare the car according to Preparations .

Removing the variable valve timing (VVT) unit

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Remove

1. the plug at the front edge of the variable valve timing (VVT) unit (TORX 55).
2. the center screw in the variable valve timing unit (TORX 55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit. A small amount of oil may run out. Place paper underneath.

Remove

1. timing belt pulley's screws. Use counterhold «9995199»(ref-403953-S15123702502011061000000) .
2. the timing gear pulley
3. tool «9995452»(ref-403953-S02369714572011061000000) .
4. the screw holding the inner timing cover to the cylinder head.

Timing belt pulley without VVT-unit: -Remove - Timing belt pulley, removing . - Remove 9995452 .

Install the adjustment tool.

Remove

1. front air baffle.
2. the support between the cylinder block and the intake manifold.
3. the starter motor mounting screws.

Place the starter motor to one side.

Remove the blind cover plug and the sealing washer.

Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.

Install gauge 9995451 . Make sure that the gauge bottoms against the engine block.

Turn the crankshaft back counter-clockwise until it stops against the drift.

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Installing VVT-unit

Install the timing gear pulley using the center screw on the camshaft.

Ensure that the markings on the timing gear pulleys/upper timing cover correspond. Do not tighten.

Installing the timing gear pulley

Install

1. the upper timing cover.
2. timing belt pulley without VVT on the camshaft. Use two screws positioned so that the markings on the timing belt gears/upper timing gear cover match. Do not tighten.

Install the timing belt on the timing gear pulleys.

Note. Adjust so that the screws in the timing gear pulley without variable valve timing do not reach the limit position in the oval holes.

Tension the timing belt

Note. This adjustment is to be made with a cold engine. Suitable temperature is approximately 20°C/67°F. At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.

The image shows the indicator position at different engine temperatures.

1. The belt shall be tight between the inlet camshaft gear, idler gear, and crankshaft.
2. Fix the belt tensioner center screw in position and turn the belt tensioner eccentric counter clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
3. Hold the eccentric secure and tighten the center screw. Torque tighten to 20 Nm .

Scheme 160

Tighten the centre screw on the timing gear pulley with VVT. Tighten to 90 Nm .

Install the plug. Tighten to 35 Nm .

Install the third screw on the timing belt pulley without VVT. Tighten with 20 Nm .

Remove the adjustment tools.

1. Press the belt to check that the indicator on the tensioner moves easily.
2. Position the upper timing cover.
3. Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond NOTE: Check that the indicator on the belt tensioner is within the marked area.
4. Remove the upper timing cover.

Reset the car. See Installing the timing covers .

See Replacing spark plugs

Replacing the idle air control (IAC) valve

See Replacing the idle air control (IAC) valve

Replacing the mass air flow (MAF) sensor

See Replacing the mass air flow (MAF) sensor

Replacing the turbocharger (TC) control valve

See Replacing the turbocharger (TC) control valve

Replacing the variable valve timing (VVT) control valve

See Replacing the variable valve timing (VVT) control valve

Replacing the variable valve timing solenoid

See Replacing the variable valve timing solenoid

See Camshaft seals, replacing

See Crankshaft seal rear, replacing

See Cylinder head/gasket, replacing

See Removing turbocharged engines with the transmission

See Replacing the cover on top of the engine

See Replacing the oil pump and front crankshaft seal

See Replacing the timing belt

See VVT-unit, replacing/adjusting

See Replacing spark plugs

See Replacing the idle air control (IAC) valve

See Replacing the mass air flow (MAF) sensor

See Replacing the turbocharger (TC) control valve

See Replacing the variable valve timing (VVT) control valve

See Replacing the variable valve timing solenoid

See Camshaft seals, replacing

See Crankshaft seal rear, replacing

See Cylinder head/gasket, replacing

See Removing turbocharged engines with the transmission

See Replacing the cover on top of the engine

See Replacing the oil pump and front crankshaft seal

See Replacing the timing belt

See VVT-unit, replacing/adjusting

Remove the oil dip stick and pipe. Raise the car.

Drain the engine oil. See Engine oil, draining .

Remove the support brace between the control arms.

Removing the front-rear member

Remove

1. the front and rear splash guards under the engine
2. the heat deflector plate in front of the output shaft
3. the nuts from the engine mountings at the front and rear edges
4. four screws (two long and two short)
5. the two screws from the engine mountings. Remove the front-rear member.

Scheme 161

Applies to 98- model year only

Remove the four screws from the oil cooler.

Detach the oil cooler from the oil pan. Leave the oil cooler hanging from the coolant hoses.

Removing the oil pan

Slacken off all the screws holding the oil pan.

Remove all but four screws. It is recommended that the four screws in the corners of the pan are left in place.

Carefully tap the oil pan until the joint and its liquid gasket releases. Use a rubber mallet.

Remove

1. the four remaining screws
2. the oil pan.

Cleaning

Clean the gasket surfaces on the oil pan and cylinder block. Use a razor blade or a gasket scraper and gasket solvent 116 1440 .

Scheme 162

Apply liquid gasket 116 1059-9 to the oil pan. Use roller 9511205 .

Install

1. new O-rings
2. the oil pan. Secure the oil pan loosely using a few screws
3. remaining screws.

Scheme 163

Press the oil pan against the transmission. Tighten the screws (1), (2), (3) and (4). Tighten to 3 Nm . Tighten the screws (5). First tighten to 25 Nm . Then tighten to 48 Nm . Tighten all screws in the oil pan joint. Tighten to 17 Nm . Start at the transmission and continue forwards in pairs.

Applies to 98- model year only

Connect the oil cooler to the oil pan. Use four screws. Tighten to 17 Nm . Use new O-rings.

Installing the front-rear member

Install the front-rear member on the front engine mounting.

Press the engine forward. Secure the front-rear member on the rear engine mounting.

Install the front-rear member to the body. Use four screws. Tighten to 69 Nm .

Tighten the screws in the engine mountings. Tighten to 55 Nm .

Install

1. the heat deflector plate in front of the output shaft. Tighten to 10 Nm
2. the support strut between the suspension turrets. Tighten to 55 Nm .

Install new oil filter. See

1. model year -97 , «Installing the oil filter, model year -97»(ref-461624-S12853496842012040200000)
2. model year 98- , «Installing the oil filter, model year 98»(ref-461624-S09313734102012040200000) .

Install

1. the oil plug with a new gasket. Tighten to 35 Nm
2. dip stick with pipe. Use a new O-ring. NOTE: Check that the O-ring is correctly positioned.

Fill with engine oil. Run the engine to operating temperature.

Check for oil leaks from the oil pan or oil cooler.

Install the front and rear splash guards under the engine.

Check the oil level. Top up as necessary.

Replacing the oil and oil filter

Special tools

9995458

9995679

Warning

1. Extended and repeated contact with oil can cause skin to dry out. This can result in itchiness, dry skin, eczema and other skin complaints.
2. Used oil is more dangerous than new oil
3. Used oil may contain contaminants that are a health risk
4. Avoid skin contact, especially with engine oil
5. Use protective gloves if necessary.
6. Avoid oil soaked rags and cloths
7. Wash thoroughly after skin contact with oil, especially before meals
8. Use a skin cream to prevent the skin drying.

Draining engine oil

1. Remove the drain plug
2. Replace the copper washer
3. Install the drain plug and tighten to 35 Nm .

Removing the oil filter, model year -97

Scheme 164

Remove the rear engine splashguard

Use oil filter wrench 9995458 .

Wipe up any spilled oil (use kitchen paper for example).

Clean the engine contact surface.

Removing the oil filter, model year 98

Scheme 165

Remove the rear engine splashguard.

Use oil filter wrench 9995679 .

Wipe up any spilled oil (use kitchen paper for example).

Remove the oil filter from the housing.

Clean the housing and the engine.

Installing the oil filter, model year -97

Scheme 166

Brush oil on the gasket.

Screw the filter on by hand until the gasket touches the gasket surface. Tighten a further 1/2-3/4 turn.

Fill oil.

Install the rear engine splash cover.

Installing the oil filter, model year 98

Install the filter in the housing.

Install the housing on the oil sump. Use oil filter wrench 9995679 .

Tighten with 25 Nm .

Install the engine splash cover.

Filling with oil

Top up oil. See Lubricants, engine .

Start the engine and check for leakage.

Stop the engine and give the oil time to run down into the sump. Then check the oil level. Top up if so required, but do not overfill.

Wipe the engine compartment clean. Make sure that the steering wheel and gear lever are clean.

Replacing the dual mass flywheel

Special tools

9995112

9995678

Preparatory work

1. To remove the transmission from turbocharged engines, see «Removing»(ref-441309-S42449177852011121500000) . For engine B4204S2, see «Removing the transmission»(ref-461627-S20291698182012040200000) .
2. Remove clutch driven plate B4204S2, see «Removal»(ref-461623-S26055550342012040200000) .

Removing the flywheel

1. Remove the engine speed (RPM) sensor assembly with the bracket. Turbocharged engines: to replace the oil seal for the crankshaft, see «Replacing rearmost crankshaft retaining ring»(ref-441341-S15244860922011121500000) . B4204S2 engines: to replace the oil seal for the crankshaft, see «Crankshaft seal rear, replacing»(ref-441341-S14635139632011121500000) .
2. Slacken off the 10 screws for the flywheel crosswise. Lift out the flywheel. Turbocharged engines: to replace the oil seal for the crankshaft, see «Replacing rearmost crankshaft retaining ring»(ref-441341-S15244860922011121500000) . B4204S2 engines: to replace the oil seal for the crankshaft, see «Crankshaft seal rear, replacing»(ref-441341-S14635139632011121500000) .
3. Check the rear oil seal on the crankshaft for leakage. Clean if necessary. Turbocharged engines: to replace the oil seal for the crankshaft, see «Replacing rearmost crankshaft retaining ring»(ref-441341-S15244860922011121500000) . B4204S2 engines: to replace the oil seal for the crankshaft, see «Crankshaft seal rear, replacing»(ref-441341-S14635139632011121500000) .

Installing the flywheel

Use tool 9995678 , with 3 studs and nuts.

1. Ensure that the crankshaft flange and flywheel mating surfaces are completely clean.
2. Install the 3 studs as shown. Turn the short thread length towards the crankshaft.
3. Install the flywheel. NOTE: Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel. There is a marking to show the position of the guide hole.
4. Align gear sector «9995112»(ref-403953-S01318438012011061000000) .
5. Pull the flywheel towards the crankshaft with the three nuts on special tool «9995678»(ref-403953-S14391401472011061000000) .
6. The turned section of the nut must be turned towards the flywheel. NOTE: It is important that the flywheel bears on the crankshaft flange before the other screws are installed.
7. Install the other screws. Use new screws. Tighten the screws crosswise to 45 Nm .
8. Remove special tool «9995678»(ref-403953-S14391401472011061000000) . Install three new screws. Tighten the screws to 45 Nm .
9. Angle-tighten all the screws crosswise to 65° .
10. Install the engine speed (RPM) sensor assembly with the bracket. Tighten the screws to 10 Nm .

Reinstall the transmission

Note. To install the transmission on turbocharged engines, see Installing . For engine B4204S2, see Transmission, installing .

Special tools

9995112

9995651

9991801

9995678

9997174

9512050

Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Removing the flywheel and carrier plate

Remove the gearbox

1. See «Removing/installing the transmission»(ref-461580-S02486235712012040200000) .

Remove the flywheel/carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Removing the seal

Note. Do not damage the mating surfaces of the crankshaft and cylinder block.

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Note. To clean the crankshaft, use cloth 9511024.

Installing the sealing ring

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool: 9997174 . Discard the old screws for the flywheel.

Installing flywheel and carrier plate

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as shown. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel/carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel/carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel/carrier plate.

1. Install the other screws. Tighten crosswise to 45 Nm .
2. Replace the 3x special screws with new standard screws. Tighten crosswise to 45 Nm .
3. Then angle-tighten all 10x screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Flywheel: 65° . Carrier plate 50° .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Installing the gearbox

Install the gearbox

1. See «Removing/installing the transmission»(ref-461580-S02486235712012040200000) .

Checking the engine

Test drive the car to check the function of the engine and the gearbox.

Checking/replacing the clutch driven plate and self-adjusting clutch

Special tools

9995112

9995662

9995663

9995677

Note. Remove the transmission from turbocharged engines, see Removing . For engine B4204S2, see Removing the transmission .

Block the flywheel

Scheme 167

Align gear sector 9995112 .

Set the clutch automatic adjustment

Use counterhold 9995677 .

Align the counterhold. See Aligning the counterhold for automatic clutch adjustment .

Scheme 168

The three pins on the counterhold lock the automatic adjustment.

Position the tool as shown.

Ensure that all the three pins as shown enter the groove in front of the tension springs for the automatic adjuster.

Press the ring against the pressure plate. Pull out the counterhold springs. Secure the three hooks in the center holes of the outer edge. See Removal .

Scheme 169

Install compression tool 9995662 , together with the conversion kit on the clutch.

Ensure that the hooks engage correctly. Ensure that the hooks do not trap the adjuster springs.

Center the compression tool.

Screw in the compression tool, at the same time checking that the tool hooks are in place.

Compress the clutch so that the automatic adjuster is not under load.

If the clutch is worn, turn the counterhold for automatic adjustment to the original position marking. The marking consists of two stamped arrows.

Then continue to screw in the compression tool until the diaphragm spring has pressed the pressure plate to a free position.

A click can be heard when the clutch pressure plate snaps out.

Removing the clutch and the clutch driven plate

Scheme 170

Note. Do not allow the diaphragm spring to be under load for a long period of time. Remove the load as soon as possible. Leave the compression tool in position.

Note. Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.

Scheme 171

Leave the compression tool and fixing ring on the clutch if the clutch is to be reinstalled.

Wipe the clutch with a dry cloth.

Check carefully for damage through over heating, cracks, scoring or other damage to the friction surface.

Check that spring is not damaged or broken.

Scheme 172

Wipe the pressure plate friction area clean.

Check any out-of-true carefully. Use a ruler and a feeler gauge. Out-of-true is permitted in one direction only.

Out-of-true must not exceed 0.2 mm . If out-of-true is greater, replace the clutch.

The clutch must be replaced as a complete unit.

Scheme 173

Wipe off clutch driven plate using a dry cloth. The cloth must be free of oil and contaminants.

Check the clutch carefully for signs of wear, damage through overheating, cracking or other damage.

Note. The clutch driven plate must always be replaced if there are radial ripples on the friction coating. The clutch driven plate must also be changed if there is oil or grease on it.

Check that there are no cracks or large scratches on the flywheel

Replace the flywheel according to Replacing the dual mass flywheel .

Install the clutch driven plate centering tool

Scheme 174

Use centering tool 9995663 . The conversion kit is included.

Remove the cone from the centering tool.

Install the centering tool in the flywheel center as far in as possible.

Use a ring spanner as a counterhold. Tighten the outer socket so that the drift expander locks the centering tool.

Ensure by touch that the centering tool is secured in the crankshaft.

Scheme 175

Install the cone on the centering tool. Tighten the cone by hand . Secure the clutch driven plate.

Note. Tightening tools must not be used on the cone or damage may be caused to the clutch driven plate.

Install the tools on the clutch

Install counterhold 9995677 . See Aligning the counterhold for automatic clutch adjustment .

Install compression tool 9995662 . See Installing the compression tool .

First tighten the center screw on the compression tool to contact, then compress the clutch.

Note. When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened 4.5 - 5 turns or until a clear click is heard .

Scheme 176

Check that the clutch automatic adjustment is secured with counterhold: 9995677 .

Install the clutch and locate on the guide pins. The compression tool center screw is hollow so that it can be threaded onto the centering drift.

Check that the clutch is in contact with the flywheel all around its circumference.

Carefully tighten the six screws crosswise so that the clutch is guided up onto the guide pins and is in contact all around the circumference of the flywheel.

Tighten the screws crosswise to 25 Nm .

Scheme 177

Screw out the center screw. Remove the compression tool.

Note. Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.

Remove the clutch driven plate centering cone.

Remove the socket. Tap the centering tool lightly with a rubber mallet so that the expander releases. Use a rubber mallet so that the threads are not damaged. Remove the centering tool.

Remove the hooks. Remove the counterhold.

Remove the flywheel gear sector.

Note. To install the transmission on turbocharged engines, see Transmission, installing . For engine B4204S2, see Transmission, installing .

See Replacing the dual mass flywheel

See Replacing the dual mass flywheel

Removing the timing belt and mechanical timing belt tensioner

Remove the timing belt according to Remove timing belt at the top side .

Remove the timing belt tensioner. Remove the idler pulley. Remove the screw securing the inner timing cover to the cylinder head.

Raise the car.

Remove the vibration damper.

Scheme 178

Remove

1. the two screws (1) securing the inner timing cover to the cylinder block
2. the lower belt guard at the oil pump housing.

Press the inner timing cover off the flange around the coolant pump. Start at the lower edge of the pump.

Hold the cover out of the way. Remove the piston cooling valve (2) and the seal washer.

Install

1. a new piston cooling valve (2) with a new seal washer. Tighten to 35 Nm
2. the inner timing cover. First press the cover into place over the flange at the top of the coolant pump. Then press the remaining section of the cover into place over the flange around the pump. Check that the cover is correctly positioned
3. the two screws (1) securing the inner timing cover to the cylinder block
4. the lower belt guard.

Install

1. the screw securing the inner timing cover to the cylinder head
2. idler pulley. Tighten to 25 Nm
3. the timing belt tensioner. Screw in the center screw by hand. Ensure that the fork on the tensioner centers above the cylinder block rib. Check that the Allen hole on the eccentric is at "10 O'CLOCK"
4. the vibration damper.

Install the timing belt according to Installing the timing belt .

Replacing piston cooling valves

See Replacing piston cooling valves

See Replacing piston cooling valves