Engine - Overhaul Instructions: Other Volvo XC90 I

BALANCE SHAFT BEARING

Special tools T9997245 SCREW Tool number: T9997245 Tool description: SCREW Tool boards: T9997246 PRESS TOOL Tool number: T9997246 Tool description: PRESS TOOL Tool boards: T9997248 POSITION SETTING TOOL Tool number: T9997248 Tool description: POSITION SETTING TOOL Tool boards: T9997025 DRIFT HALDEX CLUTCH Tool number: T9997025 Tool description: DRIFT HALDEX CLUTCH Tool boards: T9997247 DRIFT Tool number: T9997247 Tool description: DRIFT Tool boards

Scheme 842

Scheme 843

Scheme 844

Scheme 845

Scheme 846

Scheme 847

see 9997245 see 9997246

Scheme 848

Scheme 849

Scheme 850

Scheme 851

Scheme 852

Scheme 853

Scheme 854

Scheme 855

see 9997248 see 9997025

Scheme 856

Scheme 857

Note. Make sure that these components are installed to the noted removal position.

Note. Make sure that the seal is correctly located.

Scheme 858

Scheme 859

see 9997247

Scheme 860

Scheme 861

Torque: M10

50 Nm

Scheme 862

Torque: M8

24 Nm

Torque: M6

10 Nm

INSTALLING FRONT CRANKSHAFT SEAL

See OIL PUMP / CRANKSHAFT SEAL, FRONT, REPLACING .

Scheme 863

Note. The timing gear pulley can only be installed in one position on the crankshaft journal splines (see the illustration).

Carefully tap in the timing gear pulley with a rubber mallet.

Scheme 864

Install

1. idler pulley. Tighten
2. the belt tensioner and the center screw so that the tensioner fork is centered over the cylinder block rib. Do not tighten
3. the lower belt guard at the oil pump
4. the fuel delivery line.

INSTALLING THE TIMING GEAR PULLEY FOR THE CAMSHAFTS

Note. The purpose of the "Installing the timing gear pulley" section described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Scheme 865

Note. Do not turn counter clockwise during this procedure.

Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit.

Press the variable valve timing unit and timing gear pulley onto the camshaft.

Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly. Turn the variable valve timing unit counter-clockwise as far as it will go. Remove the center screw.

Position the upper timing cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cogs before the marking on the upper timing cover.

Check that the timing gear pulley is still in the limit position in the oval holes. Tighten the center screw in the variable valve timing unit. Tighten. See SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES .

Check that the variable valve timing unit does not rotate when tightening. Install and tighten the center plug. See SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES .

Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond.

Scheme 866

Note. Do not turn counter clockwise during this procedure.

Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit and timing gear pulley onto the camshaft.

Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.

Turn the variable valve timing unit counter-clockwise as far as it will go. Remove the center screw. Position the upper timing cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 1/2 cogs before the marking on the upper timing cover.

Scheme 867

Check that the timing gear pulley is still in the limit position in the oval holes.

Tighten the center screw in the VVT unit. See SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES .

Check that the variable valve timing unit does not rotate when tightening. Install the center plug. Tighten. See SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES .

Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.

FINISHING

Tighten the center screw on the timing belt tensioner. Tighten to 5 Nm .

Scheme 868

Install the belt in the following order

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

Note. The variable valve timing units do not have a return spring and are easily dislodged when reinstalling the timing belt. Check that the markings are correct.

Scheme 869

This adjustment is to be made with a cold engine. A suitable temperature is approximately 20°C/68°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 illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position and reaches the limit position.

Tighten the 3 screws on the exhaust camshaft timing gear pulley. Tighten. See TIGHTENING TORQUE .

Tighten the 3 screws on the intake camshaft timing gear pulley. Tighten. See TIGHTENING TORQUE .

Scheme 870

Note. Check that the variable valve timing units are in the limit position.

Turn the eccentric back so that the indicator reaches the marked position in the center of the window.

Remember to hold the center screw secure at the same time.

Hold the eccentric secure. Tighten the center screw. Tighten. See SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES .

Check that the indicator is in the correct position.

Scheme 871

Remove

1. camshaft adjustment tools see «9995452»(ref-460875-S28994665802012033000000) from the rear edge of the camshafts
2. crankshaft stop see «9995451»(ref-460875-S29017471142012033000000)
3. the plug with a new sealing washer. Tighten. See «TIGHTENING TORQUE»(ref-476949-S36419418602012060500000) .

Scheme 872

Press the timing belt to check that the indicator on the belt tensioner moves easily.

Position the upper timing cover.

Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond.

Check that the indicator on the belt tensioner is within the marked area.

Remove the upper timing cover.

Scheme 873

Install

1. the vibration damper. Use counterhold see «9995433»(ref-460875-S01326826912012033000000)
2. the crankshaft center nut. Tighten. See «SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES»(ref-476949-S04187009702012060500000) . Remove counterhold see «9995433»(ref-460875-S01326826912012033000000)
3. the 4 screws. Tighten. See «SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES»(ref-476949-S04187009702012060500000) . Use the crankshaft center screw as a counterhold.

CHECKING THE MARKINGS AND BELT TENSION

Press the timing belt to check that the indicator on the belt tensioner moves easily.

Position the upper timing cover.

Turn the crankshaft two turns. Check that the markings on the crankshaft and timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.

Check that the indicator on the belt tensioner is within the marked area.

OIL PUMP / CRANKSHAFT SEAL, FRONT, REPLACING

Special tools

see 9995433

see 9986187

see 9995919

see 9995455

see 9512050

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

BELT DRIVE, DISMANTLING

Special tools

see 9995304

see 9995433

see 9995747

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

Scheme 874

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing belt cover.

Remove the upper timing cover.

REMOVING THE OIL PUMP

Remove the belt protection from the oil pump.

Remove the 4 screws for the oil pump.

Carefully work the oil pump out. Use a groove-cut chisel with stop lugs.

Carefully draw the oil pump past the end of the crankshaft.

Carefully clean the gasket face and mating surfaces.

Remove tool see 9995747 .

Scheme 875

Unscrew the oil pump. Note the position of the outer/inner pump wheel and the piston/spring for the relief valve.

Clean and check all components.

Check for damage and wear. Replace the oil pump in the event of a fault.

When replacing the sealing ring.

Carefully tap the sealing ring out. Use a carefully selected drift and hammer.

A new sealing ring is first installed after the pump has been installed in the cylinder block.

Scheme 876

Place the inner and outer pump wheels in the oil pump housing.

The inner pump wheel has a inset surface around the hole for alignment to the crankshaft. The inset surface should be positioned towards the sealing ring in the oil pump housing.

Install the spring and piston for the relief valve. Screw the pump together. Tighten the screws. See: TIGHTENING TORQUE .

Scheme 877

Remove the screws.

Carefully tap the pump pulley with a rubber mallet.

Work the pump loose.

Carefully clean the gasket face and mating surfaces.

Remove the inner timing belt cover.

REMOVING THE THERMOSTAT AND THERMOSTAT HOUSING

Remove the cover over the thermostat (Tx40).

Lift out the thermostat

Remove the hose for the water heated crankcase ventilation.

Remove the thermostat housing from the cylinder head.

Carefully clean the gasket face and mating surfaces.

Remove the fuel pressure line.

Scheme 878

The thermostat can be tested in warm water.

Maximum opening must occur within 2 minutes in water at opening temperature.

INSTALLING THE CRANKSHAFT TIMING GEAR PULLEY

Note. The timing gear pulley can only be installed in one position at the splines on the crankshaft journal (see the illustration).

Carefully tap in the timing gear pulley with a rubber mallet.

INSTALLING THE IDLER PULLEY AND BELT TENSIONER

Install

1. idler pulley. Tighten
2. the tensioner damping unit.
3. the belt tensioner and the center screw. Ensure that the tensioner fork is centered over the cylinder block rib. Do not tighten
4. the lower belt guard at the oil pump
5. the fuel delivery line.

CHECKING AND ADJUSTING THE VARIABLE VALVE TIMING UNIT

Check and adjust the variable valve timing unit. See: VARIABLE VALVE TIMING UNIT, CHECKING AND ADJUSTING .

Scheme 879

Install

1. the crankshaft pulley for the auxiliaries belt
2. counterhold see «9995433»(ref-460875-S01326826912012033000000) .
3. the crankshaft center nut. Tighten to 300 Nm .

Remove counterhold 999 5433.

Install the vibration damper. Use new screws. Tighten to 35 Nm . Angle tighten 50° . Use the crankshaft center nut as a counterhold.

DISMANTLING THE BELT DRIVE

Special tools

see 9995304

see 9995433

see 9995456

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

ALIGNING THE ENGINE ACCORDING TO THE MARKING

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing belt cover

Remove the upper timing belt cover.

REMOVING THE BELT TENSIONER AND IDLER PULLEY

Remove the belt tensioner and idler pulley.

Check the rolling surface and the bearings.

Check for any noise. Check for any play in the bearings.

Check that the rolling surfaces are smooth and clean.

Scheme 880

Remove

1. the fuel pressure pipe
2. the belt guard from the oil pump
3. the four oil pump screws.

Carefully work the oil pump out. Use a groove-cut chisel with stop lugs.

Carefully draw the oil pump past the end of the crankshaft.

Carefully clean the gasket face and mating surfaces.

Scheme 881

Disassemble the oil pump.

Clean and check all components.

Check for damage and wear.

In particular check the half-moon shaped insert (the surface between the suction and pressure sides).

Replace the oil pump in the event of a fault.

Assemble the oil pump.

Tighten the screws. Tighten to 6 Nm.

Scheme 882

Remove the screws.

Carefully tap the pump pulley with a rubber mallet.

Work the pump loose.

Carefully clean the gasket face and mating surfaces.

Scheme 883

Remove the cover over the thermostat (Tx40).

Lift out the thermostat and remove the gasket.

Remove the screw for the engine coolant temperature sensor cable duct.

Remove the thermostat housing from the cylinder head.

Carefully clean the gasket face and mating surfaces.

CHECKING THE OPENING FUNCTION OF THE THERMOSTAT

The thermostat can be tested in warm water.

Maximum opening must occur within 2 minutes in water at opening temperature.

INSTALLING THE WATER PUMP

Install the rear timing cover.

Screw into place at the three mounting points.

Install the water pump with a new gasket .

Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten crosswise.

Scheme 884

Use a new gasket and a new O-ring around the oil pump housing.

Screw sliding sleeve 999 5747 into place at the front of the crankshaft journal.

Press in the pump over the sliding sleeve.

Apply thread sealant, P/N 11-61 056, to all the screws for the oil pump.

Install the screws as a guide.

Carefully tap in the oil pump with a rubber mallet.

Tighten the oil pump crosswise. Tighten to 10 Nm .

Remove sliding sleeve 999 5747 .

Note. The timing gear pulley can only be installed in one position on the crankshaft journal splines (see the illustration).

Carefully tap in the timing gear pulley with a rubber mallet.

Scheme 885

Install

1. idler pulley. Tighten
2. the belt tensioner and the center screw so that the tensioner fork is centered over the cylinder block rib. Do not tighten
3. the lower belt guard at the oil pump
4. the fuel delivery line.

Scheme 886

Timing gear pulleys with variable valve timing unit

Check that the screws holding the timing gear pulley to the variable valve timing unit have been slackened off.

Press the variable valve timing unit and timing gear pulley onto the camshaft.

Install the center screw which secures the variable valve timing unit to the camshaft. Do not tighten.

Position the upper timing cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in their respective limit positions.

Hold the variable valve timing unit. Turn clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.

Check that the timing gear pulley is still in the limit position in the oval holes.

Tighten the center screw for the variable valve timing (VVT) unit. Tighten to 120 Nm .

Note. Check that the VVT unit does not rotate when tightening.

Install the center plug. Tighten to 35 Nm .

Timing gear pulleys without variable valve timing units

Install the timing gear pulley on the camshaft with two screws. Do not tighten.

Adjust the timing gear pulley so that the markings on the timing gear pulley and the upper timing cover correspond.

Scheme 887

Tighten the center screw on the timing belt tensioner. Tighten to 5 Nm .

Turn the variable valve timing unit clockwise until stop. Use a Tx 55 Torx wrench applied at the center plug.

Hold the variable valve timing unit secure in the limit position.

Install the timing belt in the following order

1. Crankshaft

2. Idler pulley

3. Intake camshaft

4. Exhaust camshaft

5. Coolant pump

6. Belt tensioner

Note. Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.

Check that the markings on the timing gear pulleys and the upper timing cover correspond.

Tighten the timing belt

This adjustment is carried out on a cold engine. A suitable temperature is approximately 20°C/68°F.

At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Scheme 888

Hold the center screw secure and turn the eccentric on the belt tensioner anti-clockwise until the tensioner indicator reaches the limit position.

Tighten the three screws securing the timing gear pulley for the exhaust camshaft to the variable valve timing unit. Tighten to 10 Nm .

Install the third screw at the timing gear pulley for the intake camshaft. Tighten the screws. Tighten to 20 Nm .

Note. The VVT unit must not be released from the limit position until after the timing gear pulleys have been tightened.

Turn the eccentric back (clockwise) so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.

Hold the eccentric secure and tighten the center screw. Tighten to 20 Nm .

Check that the indicator is in the correct position.

Remove

1. the camshaft adjustment tools see «9995451»(ref-460875-S29017471142012033000000)
2. the crankshaft stop see «9995452»(ref-460875-S28994665802012033000000) Install the plug with a new blind cover plug . Tighten to 40 Nm .

Check

Press the toothed belt to check that the indicator on the tensioner moves easily.

Press the timing belt to check that the indicator on the belt tensioner moves easily.

Position the upper timing cover.

Turn the crankshaft two turns. Check that the markings on the crankshaft and timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.

Check that the indicator on the belt tensioner is within the marked area.

DISMANTLING THE BELT TRANSMISSION

Special tools

see 9995304

see 9995433

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

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing belt cover

Remove the upper timing belt cover.

REMOVING THE CRANKSHAFT PULLEY

Use puller see 9995304 and two screws (M8 x 45 mm) with washers.

Pull off the timing gear pulley.

Remove the belt tensioner and idler pulley.

Check the rolling surface and the bearings.

Check for any noise. Check for any play in the bearings.

Check that the rolling surfaces are smooth and clean.

Scheme 889

Remove the belt protection from the oil pump.

Remove the four oil pump screws.

Carefully wiggle out the oil pump. Use a screwdriver at the pry lugs.

Carefully draw the oil pump past the end of the crankshaft.

Carefully clean the gasket face and mating surfaces.

CHECKING THE OIL PUMP

Disassemble the oil pump.

Clean and check all components.

Check for damage and wear.

Replace the oil pump in the event of a fault.

Assemble the oil pump. Tighten to 6 Nm .

REMOVING THE COOLANT PUMP / TIMING BELT COVER

Remove the screws.

Carefully tap the pump pulley with a rubber mallet.

Work the pump loose.

Carefully clean the gasket face and mating surfaces.

Remove the inner timing belt cover.

Scheme 890

Remove the cover over the thermostat (Tx40).

Lift out the thermostat

Remove the hose for the water heated crankcase ventilation.

Remove the thermostat housing from the cylinder head.

Carefully clean the gasket face and mating surfaces.

Remove the fuel pressure line.

The thermostat can be tested in warm water.

Maximum opening must occur within 2 minutes in water at opening temperature.

Scheme 891

On engines manufactured of aluminum the camshaft bearing housing (1) cylinder block (2) and the intermediate section (3) may be caulked.

Note. The cylinder heads that are chill-cast may not be caulked.

Each individual case is assessed as to whether caulking can be carried out or not depending on the location of the oil leakage.

Scheme 892

Caulking involves in the event of leakage knocking the material together using a special caulking tool.

Two caulking tools are required. Use center punches (1). Grind down the tips so they become round. One is to be ground so the rounded tip (A) is 2 mm. The other is ground so the rounded tip (B) is 4 mm.

Note. Use the protective goggles supplied with the leak tracing kit.

Use: Isopropanol, 1161721

Use an UV light to localize the pore. Carefully wash round the pore with Isopropanol. Check with a UV light that all the oil has been removed.

Scheme 893

If the pore is small, it is sufficient to place the tool (2 mm) directly on the pore and hit it with a copper or plastic hammer. If the pore is larger, angle the tool (2 mm) and drive the material in a circle toward the pore (2). If there is a lip around the pore, caulking (tool 4 mm) should be carried out in a spiral form toward the pore (3).

Scheme 894

Drive the material toward the pore (1) using the 2 mm tool. Seal using the 4 mm tool (2).

Use: Isopropanol, 1161721

Wash with Isopropanol. Check with a UV lamp that there is no oil around the leakage point.

Test drive for 45 minutes as set out below to reach an oil temperature of about 80°C.

1. Allow the engine to idle for 20 minutes.
2. Test drive the car for 15 minutes.
3. Allow the engine to idle for a further 10 minutes.

Check using a UV light that the sealed area no long leaks. If leakage remains, repeat the caulking.

CAULKING

see CAULKING

see CAULKING

see CAULKING

CLEANING

Ensure that the all components are completely clean.

Blow clean the oil ducts in the block, intermediate section and oil pan.

Scheme 895

Install the piston cooling nozzles. Tighten to 17 Nm .

Scheme 896

Install the piston cooling valve. Use a seal washer. Tighten to 38 Nm .

Scheme 897

Wipe clean the bearing recesses in the block and the intermediate section.

Check that the components are clean and undamaged.

Check the classification of the block and crankshaft.

The classification marking is at the rear edge of the block and the crankshaft. The classification is read from digits 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing positions are numbered starting at the front of the engine.

SELECTING BEARINGS

Install the main bearings in the cylinder block and the intermediate section. See the table.

The axial bearing is positioned at bearing recess 5.

For example: The marking on the block at bearing recess 1 is B. The marking on the crankshaft at the corresponding bearing recess is C.

Therefore the bearing in the block is marked red and the bearing in the intermediate section is marked yellow.

Note. The thickest bearing halves must always be installed in the intermediate section. This is in order to obtain a center line that is as straight as possible.

Scheme 898

Wipe the surfaces dry.

Apply liquid gasket 11 61 059 on the intermediate section. The surface must be completely covered without any excess. Use roller see 9512767

Thoroughly lubricate all the bearing shells and the surface of the axial bearing.

Scheme 899

Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.

Lift these and the front of the crankshaft.

Carefully position the crankshaft in the block.

The crankshaft must not be turned before the intermediate section has been torque tightened. Position the intermediate section.

Lubricate and install all the screws.

Note. Use new M10 bolts.

Install the intermediate section and the screws on the exhaust side at bearing recesses 2 and 5.

Pull down the intermediate section.

Tighten the screws in the following order

Tighten the screws in sequence from the center and outwards.

Scheme 900

Assemble the connecting rod. Check that the cover is facing the correct direction. Tighten to 20 Nm .

Secure the large end of the connecting rod in a vise with soft jaws (copper or aluminum).

Mark both halves with the cylinder number. Use a center punch or number punch.

The bearing shell with the black color coding on the side must be installed in the connecting rod.

Scheme 901

Use piston ring pliers.

Turn the piston rings so that the openings are offset as illustrated.

A=Compression ring. The text on the piston ring must be upwards.

B=Scraper ring. Chamfered edge must face downwards.

C=Oil ring. Three sections, identical on all sides.

First install the expander ring (C), then the two other rings over the expander ring.

Note. Incorrect positioning increases oil consumption.

Scheme 902

There is an arrow on top of the piston. This must be turned forwards in the cylinder block.

The connecting rods are symmetrical and can be turned freely. Marked rods however must be turned in the same direction.

Assemble the connecting rod and piston with the piston pin.

Check that the classification of each cylinder/piston diameter and that any numbering of the connecting rod correspond.

Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston. The opening must be vertical.

Wipe clean around the bearing recess in the connecting rod and the cap.

Install the bearing shells.

If new bearing shells are used, these must be checked for color coding.

Note. Bearing shell with a black color marking on the side shall be installed in the connecting rod.

Scheme 903

Use a cylinder ring compressor.

Lubricate the cylinder bore, the pistons and the bearing shells.

Turn the crankshaft so that the connecting rod pin is at bottom dead center (BDC) for the cylinder the piston is to be inserted in.

Ensure that the engine is in a position where the cylinder bore forms as vertical a line as possible.

Note. The piston's arrow (on top of the piston) must point forwards, and make sure that the classification matches

Carefully press or tap the piston down (using the shaft of a hammer or similar).

When the piston releases from the piston ring compressor, turn the engine 180° in the stand.

Install tool see 9995746 in the connecting rod.

Pull the connecting rod until it secures against the big end journals.

Scheme 904

Install the cover. Check that any markings correspond.

Lubricate and install new seals. Tighten in two stages

Tighten the connecting rod cap. Acc. to TIGHTENING TORQUE

Check that the connecting rod can be moved sideways.

Note. The crankshaft must not be rotated before the connecting rod cover has been tightened.

Scheme 905

Install a new sealing ring on the suction pipe.

Carefully press the suction pipe down into the intermediate section.

Check that the sealing ring is correctly positioned.

Tighten.

Install new sealing rings for the oil pan oil ducts.

Scheme 906

Wipe the surfaces dry.

Apply liquid gasket 11 61 059 on the oil sump. Use roller see 9512767 .

The surface must be completely covered without any excess.

Position the pan and install all screws

Tighten the screws from the rear of the pan and forward.

Scheme 907

Install

1. new sealing rings in the sump
2. the oil cooler. Tighten
3. the oil filter.

Scheme 908

Use standard handle see 9991801 and drift see 9995676 .

Lubricate the drift face and thread the sealing ring onto the drift.

Tap in the seal until the drift bottoms against the block.

REMOVING THE SCREWED JOINT FROM THE INTERMEDIATE SECTION

First remove the M7 screws from the intermediate section.

Then remove the M8 screws. Start at the outer edges and work alternately towards the center.

Remove the M10 screws in the same way.

Scheme 909

Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6-8 mm.

Then carefully tap off (on the exhaust side) the intermediate section with a rubber mallet.

Lift out the intermediate section. Ensure that the bearing covers for the intermediate section come with it.

Ensure that the screws for the flywheel and carrier plate, which were installed earlier, are properly tightened. Lift them and the front of the crankshaft.

Carefully lift the crankshaft straight up.

Remove the remaining bearing covers.

Note. The bearing covers for the different bearing seatings are not interchangeable.

REMOVING THE PISTON COOLING VALVE AND NOZZLES

Remove the piston cooling valve at the front of the engine.

Remove the piston cooling nozzles.

Scheme 910

Clean the gasket surfaces on the cylinder block, intermediate section and oil pan.

Use a razor blade or a gasket scraper and / or gasket solvent ( P/N 116 1440 ).

NEW CONNECTING ROD

A new connecting rod has been introduced on certain engines.

The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated fracture surface.

Note. Blow the fracture surface clean with compressed air before reinstalling the cap.

Scheme 911

Visually check the bearing shells.

If in doubt measure out-of-round. Use a bore gauge.

For the correct diameter of the bearing recess, see CRANK MECHANISM .

CHECKING THE CONNECTING ROD IN A CONNECTING ROD ALIGNER

Check for out-of-true and twisting.

Ensure that the all components are completely clean.

Blow clean the oil ducts in the block, intermediate section and sump.

INSTALLING THE PISTON COOLING VALVE AND NOZZLES

Install the piston cooling nozzles. Tighten the screws.

Scheme 912

Install the piston cooling valve. Use a seal washer. Tighten. See SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES .

CLASSIFICATION OF MAIN BEARINGS

Wipe clean the bearing recesses in the block and the intermediate section.

Check that the components are clean and undamaged.

Check the classification of the block and crankshaft.

The classification marking is at the rear edge of the block and the crankshaft. The classification is read from digit 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing recesses are numbered starting at the front of the engine.

Note. Always use new bearings.

Bearing halves with grooves are always installed in the engine block.

Install the main bearings in the cylinder block and the intermediate section. See the table. The axial bearing is positioned at bearing recess 5

Scheme 913

1. Classification cylinder block
2. Classification crankshaft
3. cylinder block
4. Intermediate section

Example. The marking on the block at bearing position 1 is B. The marking on the crankshaft at the corresponding bearing position is C. This gives a red marked bearing in the block and a yellow marked bearing in the intermediate section.

Note. The thickest of the bearing caps must always be installed in the intermediate section. This is to keep the center line as straight as possible.

APPLYING LIQUID GASKET

Wipe the surfaces dry. Apply liquid gasket 11 61 059 to the intermediate section.

The surface must be completely covered without any excess. Use roller see 9512767 . Thoroughly lubricate all the bearing shells and the thrust bearing's surface.

MARKING THE CONNECTING ROD (WHERE APPLICABLE)

Assemble the connecting rod. Check that the cover is facing the correct direction. Tighten to 20 Nm .

Secure the large end of the connecting rod in a vice with soft jaws (copper or aluminum). Mark both halves with the cylinder number. Use a center punch or number punch.

Scheme 914

For every cylinder there is a classification letter stamped (C, D, E) on the top of the engine block.

First letter after the digit 1 corresponds to the classification of the cylinder bore in cylinder 1 and is then followed by cyl. 2, 3, 4, 5.

Cylinder selection is determined by the classification of the cylinder bore. For example: Cylinder class D must have pistons marked D etc.

INSTALLING PISTON RINGS

Note. Incorrect positioning may result in higher oil consumption.

Use piston ring pliers. Turn the piston rings so that the openings are offset as illustrated.

A=Compression ring. The text on the piston ring must be upwards.

B=Scraper ring. Chamfered edge must face downwards.

C=Oil ring. Three sections, identical on all sides. First install the expander ring (C), then the two other rings over the expander ring.

INSTALLING THE PISTONS IN THE CYLINDER BORES

Note. The arrow on top of the piston must point forwards. Ensure that the classifications correspond.

Use a cylinder ring compressor.

Lubricate the cylinder bore, the pistons and the bearing shells.

Turn the crankshaft so that the connecting rod pin is at bottom dead center (BDC) for the cylinder the piston is to be inserted in.

Ensure that the engine is in a position where the cylinder bore forms as vertical a line as possible.

Carefully press or tap the piston down (using the shaft of a hammer or similar). When the piston releases from the piston ring compressor, turn the engine 180° in the stand.

Install tool see 9995746 in the connecting rod. Pull the connecting rod until it secures against the big end journals.

INSTALLING THE OIL PUMP SUCTION PIPE

Install a new seal ring on the suction line.

Carefully press the suction pipe down into the intermediate section. Check that the sealing ring is correctly positioned.

Tighten the screws. Install new sealing rings for the oil ducts to the sump.

INSTALLING THE SUMP

Wipe the surfaces dry.

Apply liquid gasket 11 61 059 on the oil sump. Use roller see 9512767 . The surface must be completely covered without any excess. Install the oil sump and install all bolts.

Tighten the screws. Start with the rear edge of the sump and work alternately forwards.

Scheme 915

Install

1. new sealing rings in the oil pan
2. the oil cooler. Tighten the screws
3. the oil filter.

Scheme 916

Note. Use emery cloth 9511024 to clean the crankshaft end.

If necessary, wash off the oil on the rear cylinder block surface. Blow clean using compressed air.

When cleaning, work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

INSTALLING THE REAR CRANKSHAFT SEAL

Use standard handle see 9991801 and drift see 9995676 .

Lubricate the drift face. Thread the seal onto the drift. Tap in the seal until the drift bottoms against the block.

REMOVING THE SUCTION PIPE FROM THE OIL PUMP

Remove

1. the O rings for the oil ducts
2. the retaining screws holding the suction pump to the intermediate section. Work / lift out the suction pipe
3. the O-ring for the suction pipe.

Check the pipe and the strainer. Check for cracks and impurities.

CHECKING MARKINGS

Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.

Turn the crankshaft so the piston in cylinder 1 is at bottom dead center (BDC).

Check that there are markings on the cap and connecting rods. Check which way the markings are positioned (exhaust and intake side). Make a note of this.

If necessary mark with a center punch or a number punch. See MARKING THE CONNECTING ROD (WHERE APPLICABLE) .

Scheme 917

A new connecting rod has been introduced on certain engines.

The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated fracture surface.

Note. Blow the fracture surface clean using compressed air before installing the cap.

REMOVING THE PISTONS FROM THE CYLINDER BLOCK

Remove the screws for the connecting rod cover.

Lift off the cover. Ensure that the bearing cover comes with it.

Install tool in the connecting rod. Press out the connecting rod and piston.

Hold by hand so that the piston does not fall to the floor. Ensure that the bearing cover comes with it.

Place the piston and connecting rod in such a way that they will be reinstalled in the correct cylinder.

Continue with cylinders 2, 3, 4 and 5 as above.

Scheme 918

Check that the coolant guide is in place. Secure if necessary.

First remove the M7 screws from the intermediate section.

Then remove the M8 screws. Start at the outer edges and work alternately towards the center.

Remove the M10 screws in the same way.

Scheme 919

Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6-8 mm .

Then carefully tap off (on the exhaust side) the intermediate section with a rubber mallet.

Lift out the intermediate section. Ensure that the bearing covers for the intermediate section come with it.

Note. The bearing covers for the different bearing recesses are not interchangeable.

Ensure that the screws for the flywheel and carrier plate, which were installed earlier, are properly tightened. Lift them and the front of the crankshaft.

Carefully lift the crankshaft straight up.

Remove the remaining bearing covers.

Remove the piston cooling valve at the front of the engine.

Remove the piston cooling nozzles.

Clean the gasket surfaces on the cylinder block, intermediate section and oil pan.

Use a razor blade or a gasket scraper and / or gasket solvent ( P/N 116 1440 ).

Ensure that the all components are completely clean.

Blow clean the oil ducts in the block, intermediate section and sump.

Install the piston cooling nozzles. Tighten to 17 Nm .

Install the piston cooling valve. Use a seal washer. Tighten to 38 Nm .

Wipe clean the bearing recesses in the block and the intermediate section.

Check that the components are clean and undamaged.

Check the classification of the block and crankshaft.

The classification marking is at the rear edge of the block and the crankshaft. The classification is read from digits 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing positions are numbered starting at the front of the engine.

Install the main bearings in the cylinder block and the intermediate section. See the table.

The axial bearing is positioned at bearing recess 6.

For example: The marking on the block at bearing position 1 is B. The marking on the crankshaft at the corresponding bearing position is C. This gives a red marked bearing in the block and a yellow marked bearing in the intermediate section.

Note. The thickest of the bearing caps must always be installed in the intermediate section. This is keep the center line as straight as possible.

Scheme 920

Wipe the surfaces dry.

Apply liquid gasket 11 61 059 to the intermediate section. The surface must be completely covered without any excess. Use roller see 9512767 .

Thoroughly lubricate all the bearing shells and the surface of the axial bearing.

Scheme 921

Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.

Lift in these and the front of the crankshaft.

Carefully position the crankshaft in the block.

The crankshaft must not be turned before the intermediate section has been torque tightened.

Position the intermediate section.

Lubricate and install all the screws.

Install the intermediate section and the screws on the exhaust side at bearing recesses 2 and 6.

Pull the intermediate section down against the cylinder block.

Note. Use new M10-screws.

TIGHTEN THE SCREWS IN THE FOLLOWING ORDER

Tighten the screws in sequence from the center and outwards.

Assemble the connecting rod. Check that the cover is facing the correct direction. Tighten to 20 Nm .

Secure the large end of the connecting rod in a vise with soft jaws (copper or aluminum).

Mark both halves with the cylinder number. Use a center punch or number punch.

Use piston ring pliers.

Turn the piston rings so that the openings are offset as illustrated.

A=Compression ring. The text on the piston ring must be upwards.

B=Scraper ring. Chamfered edge must face downwards.

C=Oil ring. Three sections, identical on all sides.

First install the expander ring (C), then the two other rings over the expander ring.

Note. Incorrect positioning increases oil consumption.

Use a cylinder ring compressor.

Lubricate the cylinder bore, the pistons and the bearing shells.

Turn the crankshaft so that the connecting rod pin is at bottom dead center (BDC) for the cylinder the piston is to be inserted in.

Ensure that the engine is in a position where the cylinder bore forms as vertical a line as possible.

Note. The arrow on top of the piston should point forward. Ensure that the classification corresponds

Carefully press or tap the piston down (using the shaft of a hammer or similar).

When the piston releases from the piston ring compressor, remove the piston ring compressor and turn the engine 180° in the stand.

Install tool see 9995746 in the connecting rod.

Pull the connecting rod until it secures against the big end journals.

Use standard handle see 9991801 and drift see 9995676 .

Lubricate the drift face and thread the sealing ring onto the drift.

Tap in the seal until the drift bottoms against the block.

Remove the suction pipe.

Remove the O-rings from the oil ducts.

Remove the screws securing the suction pipe to the intermediate section.

Work loose and lift out the suction pipe.

Remove the suction pipe O-ring.

Check the pipe and the strainer. Clean thoroughly.

Scheme 922

Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.

Turn the crankshaft so the piston in cylinder 1 is at bottom dead center (BDC).

Check that there are markings on the cap and connecting rods and check which way the markings are positioned (exhaust / intake side). Note this.

If necessary mark with a center punch or a number punch (see later section).

A new connecting rod has been introduced on B6294S engines.

The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated fracture surface.

Note. Blow the fracture surfaces clean using compressed air before reinstalling the cap.

Remove the screws for the connecting rod cover.

Lift off the cover. Ensure that the bearing cover comes with it.

Install tool see 9995746 with thread adapter 5746-1 in the connecting rod. Press out the connecting rod and piston.

Hold by hand so that the piston does not fall to the floor. Ensure that the bearing cover comes with it.

Place the piston and connecting rod in such a way that they can be reinstalled in the correct cylinder.

Continue with cylinders 2, 3, 4, 5 and 6 as above.

First remove the M7 screws from the intermediate section.

Then remove the M8 screws. Start at the outer edges and work alternately towards the center.

Remove the M10 screws in the same way.

SEPARATING THE INTERMEDIATE SECTION FROM THE CYLINDER BLOCK

Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6-8 mm.

Then carefully tap off (on the exhaust side) the intermediate section with a rubber mallet.

Lift out the intermediate section. Ensure that the bearing covers for the intermediate section come with it.

Ensure that the screws for the flywheel and carrier plate, which were installed earlier, are properly tightened. Lift them and the front of the crankshaft.

Carefully lift the crankshaft straight up.

Remove the remaining bearing covers.

Note. The bearing covers for the different bearing recesses are not interchangeable.

Remove the piston cooling valve at the front of the engine.

Remove the piston cooling nozzles.

Scheme 923

Clean the gasket surfaces on the cylinder block, intermediate section and oil pan.

Use a razor blade or a gasket scraper and gasket solvent ( P/N 116 1440 ).

MEASURING THE CRANKSHAFT

Use a micrometer.

Measure the out-of-round and taper of the bearing journal. Measure at a number of points laterally and longitudinally.

For the correct values for the connecting rod bearing journals and main bearing journals, see CRANK MECHANISM .

CHECK THE OUT-OF-TRUE OF THE CRANKSHAFT

Use a dial indicator and magnetic holder.

Position the crankshaft with the two outer main bearings in the V block.

Turn the crankshaft and measure the radial runout on the other main bearing journals.

For the correct values, see CRANK MECHANISM .

REMOVING THE PISTON RINGS

Use piston ring pliers.

Remove coke deposits. Scrape the piston ring grooves clean with a groove cleaner or a broken and filed piston ring.

Check for damage, wear and cracks.

CHECKING PISTON RING AXIAL CLEARANCE

Use new piston rings.

For the correct values, see PISTONS .

Scheme 924

Use a micrometer and Vernier caliper.

For the correct values, see PISTONS .

CALCULATING THE RUNNING CLEARANCE OF THE PISTON

For the correct values, see PISTONS .

A new connecting rod has been introduced on B6294S engines.

The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated fracture surface.

Note. Blow the fracture surface clean with compressed air before reinstalling the cap.

CHECKING THE BEARING RECESS IN THE CONNECTING ROD BIG END

Visually check the bearing shells.

If in doubt measure out-of-round.

Use a bore gauge.

For the correct diameter of the bearing recess, see CRANK MECHANISM .

Check for out-of-true and twisting.

CRANK MECHANISM, DISMANTLING

Special tools T9995746 HOLDER (REMOVAL-PISTON/CONNECTING ROD) B 200-B 6304 Tool number: T9995746 Tool description: HOLDER (REMOVAL-PISTON/CONNECTING ROD) B 200-B 6304 Tool boards

Note. Some variation may occur. However, the essential information in the illustrations is always correct.

Note. Removal steps in this procedure may contain installation details.

Release the engine. See ENGINE BODY, EXPOSING

Remove the following components

1. oil pump and line. See «OIL PUMP»(ref-476995-S22873765022012060500000)
2. front crankshaft seal. See «CRANKSHAFT FRONT SEAL»(ref-476775-S37195018072012060500000)

Scheme 925

Scheme 926

Scheme 927

Note. Note the position of each component before removal.

Note. Make sure that these components are installed to the noted removal position.

Scheme 928

Note. Make sure that these components are installed to the noted removal position.

see 9995746

Scheme 929

Note. Make sure that these components are installed to the noted removal position.

see 9995746

1. Torque: M8 24 Nm
2. Torque: M10 50 Nm

Scheme 930

Scheme 931

Note. Note the position of each component before removal.

Note. Make sure that these components are installed to the noted removal position.

Clean the gasket surfaces on the cylinder block, intermediate section and sump.

and/or

Use: Gasket solution, 1161440

RECONDITIONING

Note. If the specified value is exceeded, a new component must be installed.

See information about specifications. See ENGINE

Scheme 932

Scheme 933

Scheme 934

see 9995418

Scheme 935

see 9999696 see 9813134

Scheme 936

Note. Make sure that the component is clean and free of foreign material.

Use: Gasket Solvent 1161847

Scheme 937

Note. Make sure that new components are installed.

Scheme 938

Scheme 939

Scheme 940

Scheme 941

Scheme 942

Scheme 943

Special tools T9995651 PULLER (REAR SEAL CRANKSHAFT) D5252T Tool number: T9995651 Tool description: PULLER (REAR SEAL CRANKSHAFT) D5252T Tool boards: T9995679 OIL FILTER WRENCH (D VERSION) Tool number: T9995679 Tool description: OIL FILTER WRENCH (D VERSION) Tool boards: T9995746 HOLDER (REMOVAL-PISTON/CONNECTING ROD) B 200-B 6304 Tool number: T9995746 Tool description: HOLDER (REMOVAL-PISTON/CONNECTING ROD) B 200-B 6304 Tool boards

Scheme 944

Scheme 945

see 9995651

Scheme 946

see 9995679

Scheme 947

Note. Only use moderate force.

Scheme 948

Scheme 949

Note. Note the position of the bearings.

Scheme 950

Note. Note the position of the bearings.

see 9995746

Scheme 951

Note. Only use moderate force.

Scheme 952

Note. Note the position of the bearings.

Scheme 953

Note. Note the position of the bearings.

MEASURING THE CYLINDER BORE

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

Scheme 954

First clean the cylinder bores and check them visually.

Measure the cylinder bores. Use a bore gauge (50-100 mm), a micrometer and a micrometer stand.

Set the micrometer to maximum cylinder bore diameter tolerance using the marking on the cylinder block.

Calibrate the bore gauge in the micrometer.

Scheme 955

Take measurements for the greatest amount of wear across the engine, just before the upper limit position.

Take measurements for the lowest amount of wear along the length of the engine, at the lower limit position.

CLASSIFICATION MARKING

Each cylinder is stamped with a classification letter (C, D or E) at the rear edge of the cylinder block.

Cylinder bore diameter: See CYLINDER BLOCK .

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

First clean the cylinder bores and check them visually.

Measure the cylinder bores. Use a bore gauge (50-100 mm), a micrometer and a micrometer stand.

Set the micrometer to maximum cylinder bore diameter tolerance using the marking on the cylinder block.

Calibrate the bore gauge in the micrometer.

CHECKING FOR WEAR

Take measurements for the greatest amount of wear across the engine, just before the upper limit position.

Take measurements for the lowest amount of wear along the length of the engine, at the lower limit position.

Each cylinder is stamped with a classification letter (C, D or E) at the rear edge of the cylinder block.

Cylinder bore diameter: see scheme 298

INSTALLING THE CYLINDER HEAD

Special tools

see 9512050

see 9512767

see 9995450

see 9995451

see 9995452

see 9995454

see 9995718

see 9995719

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

INSTALLING TAPPETS AND CAMSHAFTS

See VALVE CLEARANCE .

Scheme 956

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

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

Apply liquid gasket 11 61 059 to the camshaft cover. The surface must be fully covered without any excess. Use roller see 9512767

Note. Make sure that no liquid gasket gets in to the oil channels.

Scheme 957

Lubricate the camshaft lobes, the camshaft bearing surfaces and the tappets.

Install the camshaft cover.

Install 2 press tools see 9995454 .

Pull the camshaft cover alternately down, keeping it parallel to the cylinder head with the press tools

Install all the screws and tighten.

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Install the control valve for the variable valve timing unit with a new gasket. Tighten.

Scheme 958

Use drift see 9995718 on camshafts with VVT units. Use drift see 9995719 on camshafts without VVT.

Use new seals. Lubricate the surface of the seal that the camshaft rotates against.

Tap in the seal until the drift bottoms against the end of the camshaft.

Scheme 959

Use drift see 9995450 .

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

Install the seal.

Press in the seal until the drift bottoms out.

Note. If there are wear grooves on the camshaft, the seal can be pressed in another 2 mm by reversing the tool's sleeve.

Scheme 960

Use camshaft tool see 9995452 .

Note. The camshafts must not be turned more than is listed in the text below. The valves may be damaged

Screw the adjustment tool sections together into one.

Check that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

MEASURING AND RECONDITIONING THE CYLINDER HEAD

Special tools

see 9986052

see 9995219

see 9995222

see 9995379

see 9995748

see 9995764

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Scheme 961

Lift out the tappets. Mark up the tappets so that the original positions can be established.

Use a suction cup to remove the tappets.

Check for wear on the tappets. Measure if necessary.

Tappets, dimensions: See TAPPETS .

Scheme 962

Use valve spring compressor see 9986052 with attachment claw see 9995748 .

Remove

1. the valve locks
2. the upper valve collars
3. the valve springs
4. the valves.

Note. Keep track of the position of the moving parts.

Scheme 963

Use tool see 9995219 .

Remove the valve stem seals and the lower valve collars.

Clean the cylinder head

1. the gasket faces
2. the combustion chambers
3. the inlet and exhaust ports
4. the valve seats.

Scheme 964

Clean the spark plug threads (tap M14 x 1.25).

Clean the valves, valve springs and collars.

Visually check for damage.

Regrind the seats if unsure about cracks. See VALVE SEATS .

Checking the cylinder head for distortion

Check the flatness of the cylinder head. Use a steel rule and feeler gauges. See CYLINDER HEAD .

CHECKING FOR WEAR IN THE VALVE GUIDES

Measure the wear in the valve guides. Use a dial indicator and magnetic holder. Lift the valve approximately 2-3 mm from the seat when carrying out the check.

Play between the valve and valve guide: See VALVE GUIDES .

CHECKING THE HEIGHT OF THE VALVE STEMS

Use camshaft adjustment tool see 9995222 .

Position the camshaft adjustment tool in the camshaft bearing recesses.

Measure the height of the valve stem using Vernier calipers through the hole in camshaft adjustment tool. See VALVES .

Scheme 965

Lubricate the valve stems and the upper ends of the valve guides.

Install

1. the lower valve spring collars
2. the valves in their positions.

Install the protective sleeve (included in the gasket kit) on the valve stem.

Note. The protective sleeve must be installed on the valve stem when the valve stem seal is installed.

Lubricate the protective sleeve (1) and install it on the valve stem.

Scheme 966

Lubricate the valve stem seal (2).

Press down the seal past the protective sleeve with your finger.

Press the seal down. Use tool see 9995764 . Press with manual force until the tool stops against the lower valve spring washer.

Remove the tool. Pull off the protective socket.

Scheme 967

Install the valve spring. Install the valve spring washer.

Compress the valve spring so that the three valve lock tracks are visible. Use valve spring compressor see 9986052 with attachment claw see 9995748 .

Note. Do not compress more than is absolutely necessary. The valve stem seal may be damaged.

Install the valve locks.

Check that valve locks are in the correct position when the spring is not loaded.

Repeat the procedure with the remaining valves.

REMOVING THE CYLINDER HEAD

Special tools

see 9995199

see 9995452

see 9995454

see 9995670

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

Scheme 968

Install tool see 9995452 on the rear edge of the camshafts.

Slacken off the screws securing the timing gear pulley to the variable valve timing unit.

Remove the plug at the front edge of the variable valve timing unit (Tx 55).

Remove the center screw from the variable valve timing unit (Tx 55).

Carefully pull out the camshaft pulley with the variable valve timing unit.

The following applies to camshafts without variable valve timing

Remove the screws.

Pull off the camshaft pulley.

Remove tool 999 5452

Scheme 969

Remove the control valve from the variable valve timing unit.

Remove the spark plugs from cylinders 1 and 5.

Install 2 tools see 9995454 , leaving a 2-3 mm gap to the camshaft cover.

Ensure that the screw in the spark plug well is tightened as far as it will go.

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

Scheme 970

Remove

1. the camshaft cover with pliers see «9995670»(ref-460875-S01119481112012033000000) by the snap-in lugs. Start with cylinder 1 and work alternately backward
2. the wing nuts approximately 2 turns. Repeat the procedure with the pliers.

Remove

1. tool 999 5454
2. the camshaft seals at both the front and rear edges
3. the camshaft cover
4. the camshafts. Work loose and lift at the same time. NOTE: Take care not to damage the axial bearings.

Scheme 971

Remove the pipe screw for the water heated crankcase ventilation at the rear edge of the cylinder head.

Slacken off the screwed joint for the cylinder head. Start at the sides and work alternately towards the center.

Lift out the cylinder head.

Note. Take care not to damage the mating surfaces.

REMOVING TAPPETS

Note. Magnets must not be used when lifting out the tappets.

Lift out the tappets. Mark up the tappets so that the original positions can be established.

Use a suction cup to remove the tappets.

Check for wear on the tappets.

REMOVING VALVES

Use valve spring compressor see 9986052 with attachment claw see 9995748 .

Remove

1. the valve locks
2. the upper valve collars
3. the valve springs
4. the valves.

Note. Keep careful track of the position of the moving parts.

REMOVING VALVE STEM SEALS

Use tool see 9995219 .

Remove the valve stem seals and the lower valve collars.

Clean the cylinder head

1. the gasket faces
2. the combustion chambers
3. the inlet and exhaust ports
4. the valve seats.

CHECKING THE CYLINDER HEAD

Clean the spark plug threads (tap M14 x 1.25).

Clean the valves, valve springs and collars.

Visually check for damage.

If you are unsure, replace the cylinder head.

Measure the wear in the valve guides. Use a dial indicator and magnetic holder. Lift the valve approximately 2-3 mm from the seat when carrying out the check.

Clearance between the valve and valve guide

Clearance between new components: Inlet/Exhaust: 0.03 -0.06 mm .

Maximum play for used components: Inlet/Exhaust: 0.15 mm .

INSTALLING VALVE STEM SEALS

Lubricate

1. the upper end of the valve guides
2. the valve stem seal.

Install

1. the lower valve spring collars
2. the valve stem seal.

Press down the seal. Use tool see 9997012 . Press with hand force until the tool stops against the lower valve spring washer. Remove the tool.

Repeat the procedure with the remaining valve stem seals.

INSTALLING THE VALVE / VALVE SPRINGS

Lubricate the valve stem.

Install

1. the valve
2. the valve spring
3. the upper valve spring washer.

Compress the valve spring so that the three valve lock tracks are visible.

Use valve spring compressor see 9986052 and press foot see 9995748 . Install the valve collets. Check that valve collets are in the correct position when the spring is not loaded.

Repeat the procedure with the remaining valves.

CYLINDER HEAD, INSTALLING

Special tools

see 9512767

see 9995450

see 9995451

see 9995452

see 9995454

see 9995718

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

Note. For tightening torques not in the text, see TIGHTENING TORQUE .

ALIGNING THE CRANKSHAFT

Turn the crankshaft counter-clockwise (viewed from the rear of the engine) until the piston in cylinder 1 reaches top dead center (TDC).

Continue turning counter-clockwise until the piston in cylinder 1 is approximately 2-3 cm before top dead center (BTDC).

Install the crankshaft stop see 9995451 Ensure that it bottoms out against the cylinder block.

Now turn the crankshaft clockwise (viewed from the rear of the engine) until the crankshaft counter-weight is in contact with the crankshaft stop.

Install a new cylinder head gasket .

Install the cylinder head.

Use new screws .

Lubricate and install all the screws.

Tighten. See TIGHTENING TORQUE .

INSTALLING VALVE LIFTERS AND CAMSHAFTS

See VALVE CLEARANCE .

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

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

Apply liquid gasket 11 61 059 to the camshaft cover. The surface must be completely covered without any excess. Use roller see 9512767

Note. Ensure that no liquid gasket gets in to the oil ducts.

Scheme 972

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

Install the camshaft cover.

Install 2 press tools see 9995454 .

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

Install all the screws and tighten.

Remove the press tools.

Install the spark plugs. Tighten. See TIGHTENING TORQUE .

Install the control valve for the variable valve timing unit with a new gasket. Tighten.

To clean the camshaft journal and mating surface, use emery cloth P/N 951 1024 .

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Scheme 973

Use drift see 9995718 .

Use new seals.

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

Tap in the seal until the drift bottoms against the end of the camshaft.

INSTALLING THE REAR CAMSHAFT SEAL

Use drift see 9995450 .

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

Install the seal.

Press in the seal until the drift bottoms out.

Continue the work with the next sealing ring.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.

SECURING THE CAMSHAFTS

Use camshaft adjustment tool see 9995452 .

Note. The camshafts must not be turned more than is listed in the text below. The valves may be damaged

Screw the adjustment tool sections together into one.

Check that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

CYLINDER HEAD, REMOVING

Special tools

see 9995452

see 9995454

see 9995670

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

Scheme 974

Install tool see 9995452 at the rear of the camshafts.

Slacken off the screws securing the timing gear pulley to the variable valve timing unit.

Remove the plug at the front edge of the variable valve timing unit (Tx 55).

Remove the center screw from the variable valve timing unit (Tx 55).

Carefully pull out the camshaft pulley with the variable valve timing unit.

Continue with the next variable valve timing unit.

Remove

1. rear timing cover
2. tool see «9995452»(ref-460875-S28994665802012033000000) .

REMOVING THE CAMSHAFT COVER

Remove

1. the control valves for the variable valve timing units
2. the spark plugs for cylinders 1 and 5.

Install tool see 9995454 (2 x). Leave a 2-3 mm gap to the camshaft cover.

Ensure that the screw in the spark plug well is tightened as far as it will go.

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

Remove

1. camshaft cover with pliers see «9995670»(ref-460875-S01119481112012033000000) at the stop lugs. Start with cylinder 1 and work alternately backwards
2. the wing nuts approximately 2 turns. Repeat the procedure with the pliers.

Note. Do not damage the axial bearings.

Remove

1. tool see «9995454»(ref-460875-S16171066982012033000000)
2. the camshaft seals at both the front and rear edges
3. the camshaft cover
4. the camshafts. Work loose and lift at the same time.

Note. Do not damage the mating surface.

Remove the pipe screw for the water heated crankcase ventilation at the rear edge of the cylinder head.

Slacken off the screwed joint for the cylinder head. Start at the sides and work alternately towards the center.

Lift out the cylinder head.

Special tools

see 9512050

see 9512767

see 9995450

see 9995451

see 9995452

see 9995454

see 9995718

see 9995719

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Turn the crankshaft counter-clockwise (viewed from the rear of the engine) until the piston in cylinder 1 reaches top dead center (TDC).

Install the crankshaft stop see 9995451 . Ensure that it bottoms out against the cylinder block.

Now turn the crankshaft clockwise (viewed from the rear of the engine) until the crankshaft counter-weight is in contact with the crankshaft stop

Scheme 975

Install a new cylinder head gasket .

Install the cylinder head.

Use new screws .

Lubricate and install all the screws.

Tighten the screws as illustrated. Tighten the screws in the following order.

1. 20 Nm
2. 60 Nm
3. Angle-tighten 130° . Use protractor see «9512050»(ref-460875-S32936410842012033000000) .

See VALVE CLEARANCE, SETTING / ADJUSTING .

Scheme 976

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

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

Apply liquid gasket 11 61 059 to the camshaft cover. The surface must be fully covered without any excess. Use roller see 9512767

Note. Ensure that no liquid gasket gets in to the oil ducts.

Scheme 977

Lubricate the camshaft lobes, the camshaft bearing surfaces and the tappets.

Install the camshaft cover.

Install 2 press tools see 9995454 .

Pull the camshaft cover alternately down, keeping it parallel to the cylinder head with the press tools

Install all the screws and tighten.

Remove the press tools.

Install the spark plugs. Tighten to 30 Nm .

Install the control valve for the variable valve timing unit with a new gasket. Tighten.

Scheme 978

Use drift see 9995718 on camshafts with VVT units. Use drift see 9995719 on camshafts without VVT.

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

Carefully tap in the seal until the drift bottoms against the end of the camshaft.

Turbocharged engines = seal at the exhaust camshaft.

Naturally aspirated engines = seal at the intake camshaft.

Use drift see 9995450 .

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

Press in the seal until the drift bottoms out.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.

Use camshaft tool see 9995452 .

Screw the adjustment tool sections together into one.

Check that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Special tools

see 9986052

see 9995219

see 9995222

see 9995379

see 9995748

see 9995764

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Scheme 979

Lift out the valve lifters. Mark up the valve lifters so that the original positions can be established.

Use a suction cup to remove the valve lifters.

Check for wear on the valve lifters. Measure if necessary.

Valve lifters, dimensions: See TAPPETS .

Use valve spring compressor see 9986052 with attachment claw see 9995748 .

Remove

1. the valve locks
2. the upper valve collars
3. the valve springs
4. the valves.

Note. Keep track of the position of the moving parts.

Use tool see 9995219 .

Remove the valve stem seals and the lower valve collars.

Clean the cylinder head

1. the gasket faces
2. the combustion chambers
3. the inlet and exhaust ports
4. the valve seats.

Clean the spark plug threads (tap M14 x 1.25).

Clean the valves, valve springs and collars.

Visually check for damage.

Regrind the seats if unsure about cracks. See VALVE SEATS .

Checking the cylinder head for distortion

Measure cylinder head distortion Use a steel ruler and feeler gauge. See CYLINDER HEAD .

Measure the wear in the valve guides. Use a dial indicator and magnetic holder. Lift the valve approximately 2-3 mm from the seat when carrying out the check.

Clearance between the valve and valve guide: See VALVE GUIDES .

CHECKING THE VERTICAL POSITION OF THE VALVE STEM

Use camshaft adjustment tool see 9995222 .

Position the camshaft adjustment tool in the camshaft bearing recesses.

Measure the height of the valve stem using a feeler gauge through the hole in the camshaft adjustment tool. See VALVES .

Lubricate the valve stems and the upper ends of the valve guides.

Install

1. the lower valve spring collars
2. the valves in their positions.

Install the protective sleeve (included in the gasket kit) on the valve stem.

Note. The protective sleeve must be installed on the valve stem when the valve stem seal is installed.

Lubricate the protective sleeve (1) and install it on the valve stem.

Lubricate the valve stem seal (2).

Press down the seal past the protective sleeve with your finger.

Press the seal down. Use tool see 9995764 . Press down by hand until the tool stops against the lower valve spring washer.

Remove the tool. Pull off the protective socket.

INSTALLING VALVE SPRINGS

Install the valve spring. Install the valve spring washer.

Compress the valve spring so that the three valve lock tracks are visible. Use valve spring compressor see 9986052 with attachment claw see 9995748 .

Note. Do not compress more than is absolutely necessary. The valve stem seal may be damaged.

Install the valve locks.

Check that valve locks are in the correct position when the spring is not loaded.

Repeat the procedure with the remaining valves.

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Scheme 980

Camshafts with variable valve timing

Install tool see 9995452 at the rear of the camshafts.

Remove the plug at the front edge of the variable valve timing unit (Tx 55).

Remove the center screw from the variable valve timing unit (Tx 55).

Carefully pull out the camshaft pulley with the variable valve timing unit.

Camshafts without variable valve timing

Remove the screws.

Pull off the camshaft pulley.

Remove tool 999 5452.

Remove the inner timing cover.

Scheme 981

Remove the control valve from the variable valve timing unit.

Remove the spark plugs from cylinders 2 and 5.

Install 2 tools . Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is tightened as far as it will go.

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

Scheme 982

Remove

1. camshaft cover with pliers see «9995670»(ref-460875-S01119481112012033000000) at the stop lugs. Start at cylinder 1 and work alternately backwards
2. the wing nuts approximately 2 turns. Repeat the procedure with the pliers.

Remove

1. tool 999 5454
2. the camshaft seals at both the front and rear edges
3. the camshaft cover
4. the camshafts. Work loose and lift at the same time. NOTE: Take care not to damage the thrust washers.

Scheme 983

Remove the pipe screws for the coolant heated crankcase ventilation at the rear edge of the cylinder head (applies only to B6284T).

Slacken off the screwed joint for the cylinder head. Start at the sides and work alternately towards the center.

Lift out the cylinder head.

Note. Take care not to damage the mating surfaces.

Note. If the specified value is exceeded, a new component must be installed.

See information about specifications. See ENGINE

Scheme 984

Note. Only use moderate force.

see 9997417 see 9986052

Scheme 985

Scheme 986

Scheme 987

see 9995219

Scheme 988

Use: Micrometer

Scheme 989

Use: Feeler gauge

Scheme 990

Note. Only use moderate force.

see 9997012

Scheme 991

Note. Make sure that these components are installed to the noted removal position.

Note. Make sure that these components are installed to the noted removal position.

Note. Only use moderate force.

Special tools

see 9512050

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

PREPARATORY WORK

When replacing the cylinder head, the valve clearance must be checked. See: VALVE CLEARANCE, SETTING/ADJUSTING .

Scheme 992

Turn the crankshaft back approximately 45°, so that the position setting tool is straight up, so that the camshafts can rotate freely.

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

Remove

1. the cover, 4 x M6
2. chain tensioner screws, 2 x M6
3. filter x 2, discarded.

Scheme 993

Remove the cover on the intake camshafts, 16 x M6.

Note. To prevent damaging the components, ensure that the camshaft is not against the lifter.

Note the location.

Lift out the camshafts.

Remove the cylinder head's screwed joint, start with the screws closest the ends, then work alternately towards the middle.

Remove

1. the screws
2. the cylinder head.

Place the cylinder head upside down on a clean, dry absorbent covered (paper wipes for example) surface. This is to prevent damage to the gasket surface of the cylinder head.

Scrap the gasket.

ENGINE BLOCK, INSTALLING COMPONENTS

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

INSTALLING ENGINE BLOCK COMPONENTS

Note. Always use new seal washers and gaskets

Install

1. thermostat housing (B52x4x)
2. knock sensor (KS)
3. flame trap
4. the pipe screw for the water-heated crankcase ventilation.

IF IN DOUBT ABOUT THE ORDER OF ASSEMBLY SEE

Install the flywheel and carrier plate. See CRANKSHAFT SEAL REAR, REPLACING .

FOR THE CORRECT TIGHTENING TORQUES SEE

The ignition coil alignment and the wiring routing follows the illustrations below.

Scheme 994

Scheme 995

CRANKSHAFT SEAL REAR, REPLACING

Special tools

see 9995112

see 9995651

see 9991801

see 9995678

see 9997174

see 9512050

Note. As the illustrations 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

Scheme 996

Remove the gearbox

1. For gasoline 4T65 2003- see «TRANSMISSION, REMOVING»(ref-476724-S31715532142012060500000) .
2. For gasoline AW50AWD 2003- see «TRANSMISSION, REMOVING»(ref-476724-S23150694972012060500000)
3. For gasoline AW55-50 2004- see «TRANSMISSION, REMOVING»(ref-476724-S17463949182012060500000) .

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

REMOVING THE SEAL

Scheme 997

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

Remove the old seal using extractor see 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.

Scheme 998

Thread the seal onto the beveled section of the inner section of tool see 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: see 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: see 9997174 . Discard the old screws for the flywheel.

INSTALLING FLYWHEEL AND CARRIER PLATE

Scheme 999

Install

1. the flywheel and carrier plate
2. the 3 studs see «9995678»(ref-460875-S21852882082012033000000) distributed as illustrated. 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: see «9995112»(ref-460875-S36509387272012033000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool see «9995678»(ref-460875-S21852882082012033000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES»(ref-476949-S04187009702012060500000) .
2. Replace the 3 special screws with new standard screws. Tighten. See «SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES»(ref-476949-S04187009702012060500000) .
3. Then angle tighten all 10 screws crosswise. Use see «9512050»(ref-460875-S32936410842012033000000) . Tighten. See «SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES»(ref-476949-S04187009702012060500000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

INSTALLING THE GEARBOX

Install the gearbox

1. For gasoline 4T65 2003- see «TRANSMISSION, INSTALLING (2003, 2004)»(ref-476724-S32864932282012060500000) or «TRANSMISSION, INSTALLING (2005, 2006)»(ref-476724-S26394933352012060500000) .
2. For gasoline AW50AWD 2003- see «TRANSMISSION, INSTALLING»(ref-476724-S28330338762012060500000)
3. For gasoline AW55-50 2004- see «TRANSMISSION, INSTALLING»(ref-476724-S30555582072012060500000) .

CHECKING THE ENGINE

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

ENGINE BODY, EXPOSING

Special tools

see 9989721

see 9992520

see 9995112

see 9995297

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

REMOVING THE GEARBOX

HINT: Remove the lower screws (these are difficult to access) between the gearbox and engine before removing the engine and gearbox unit. The engine and gearbox unit must be placed on a suitable surface.

HINT: Relieve the transmission. Loose the remaining screws and remove the transmission carefully.

Remove the clutch. See PRESSURE PLATE / CLUTCH DRIVEN PLATE, REPLACING .

Scheme 1000

Install gear sector see 9995112 .

Remove all screws except for the uppermost screw which secures the flywheel to the crankshaft. Slacken off the uppermost screw. Leave it in place, screwed in a few turns.

Carefully work the flywheel and carrier plate loose. If necessary, use 2 groove-cut chisels. Apply these between the cylinder block and the flywheel and carrier plate.

Hold the flywheel and carrier plate and remove the final screw.

Install the engine in a stand

Use mounting stand see 9992520 , fixture see 9995297 and screw set see 9989721 .

Scheme 1001

REMOVE

Scheme 1002

REMOVE

PRESSURE PLATE / CLUTCH DRIVEN PLATE, REPLACING

Special tools

see 9995112

see 9995662

see 9995663

see 9995675

see 9995677

Note. Removing the gearbox: To remove the transmission, see TRANSMISSION - REMOVAL, REPLACEMENT AND INSTALLATION .

Note. The illustrations show a self-adjusting clutch. Where there are differences, these are noted.

Scheme 1003

Use gear sector see 9995112 .

Applies only to certain engine versions with self adjusting clutches

Secure the clutch automatic adjustment.

Use counterhold see 9995677 . Locate the counterhold, see below.

ALIGNING THE COUNTERHOLD FOR AUTOMATIC CLUTCH ADJUSTMENT

Scheme 1004

Applies only to certain engine versions with self adjusting clutches

The three pins on the counterhold lock the automatic adjustment.

Position the tool as illustrated.

Ensure that all the three pins (see the illustration) go into the groove in front of the tensioner 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. .

Use gear sector 9995112 .

Applies only to certain engine versions with self adjusting clutches

Secure the clutch automatic adjustment.

Use counterhold 9995677 . Locate the counterhold, see below.

INSTALLING THE COMPRESSION TOOL

Scheme 1005

Install compression tool see 9995662 , together with the conversion kit on the clutch. The tool is modified as described in the tool bulletin.

Ensure that the hooks grip correctly, although without clamping the adjuster springs.

Centre the compression tool and tighten the screw to light contact against the diaphragm spring. At the same time, check that the hooks on the tool are in position.

Applies only to clutches without self adjustment

Note the position of the handle with slots. Then screw in by not more than two turns .

Remove the clutch and clutch driven plate

Applies only to certain engine versions with self adjusting clutches

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

If the clutch is worn, the counterhold turns the 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.

Remove the clutch and clutch driven plate

RELIEVING THE LOAD FROM THE CLUTCH DIAPHRAGM SPRING

Scheme 1006

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

Applies only to certain engine versions with self adjusting clutches

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.

CHECKING THE CLUTCH

Scheme 1007

Wipe the clutch using a dry cloth.

Check carefully for over heating damage, cracking, scoring or other damage to the friction surface

Check that spring is not damaged or broken.

CHECKING THE PRESSURE PLATE FOR OUT-OF-TRUE

Scheme 1008

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.

CHECKING THE CLUTCH DRIVEN PLATE

Scheme 1009

Wipe off the 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 no radial ripples remaining on the friction coating. The clutch driven plate must also be changed if there is oil or grease on it.

CHECKING THAT THERE ARE NO CRACKS OR LARGE SCRATCHES ON THE FLYWHEEL

To replace the flywheel, see ENGINE - REMOVAL, REPLACEMENT AND INSTALLATION - 2 OF 2 .

SEALING MICRO-ENCLOSED SCREWS

Note. Micro-enclosed screws are used where the seal requirements are high. Loose screws are replaced or sealed with new sealing compound. Sealant "HYDRAULIC THREADSEAL" has P/N 11 61 056-5 and sealing must be carried out according to the instructions on the packet. The screws to be sealed with "HYDRAULIC THREAD SEAL" and their positions are shown below.

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

Scheme 1010

"Hydraulic thread sealant"

1. P/N 11 61 056-5
2. Use a brush and/or the packet spout to apply the sealant to the screw.
3. Avoid skin contact with the sealant.

Scheme 1011

Scheme 1012

Scheme 1013

Scheme 1014

see ENGINE BLOCK, INSTALLING COMPONENTS

EXPOSING THE ENGINE BODY

Special tools

see 9989721

see 9992520

see 9995112

see 9995297

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

REMOVING THE TRANSMISSION

HINT: Remove the lower screws (these are difficult to access) between the transmission and engine before removing the engine and transmission unit. The engine and transmission unit must be placed on a suitable surface.

HINT: Take the weight off the transmission. Remove the remaining screws. Carefully remove the transmission.

Remove the clutch

1. for M65 see «PRESSURE PLATE / CLUTCH DRIVEN PLATE, REPLACING»(ref-477025-S17798541762012060500000) .

REMOVING THE FLYWHEEL AND CARRIER PLATE

Install gear sector see 9995112 .

Remove all screws except for the uppermost screw which secures the flywheel to the crankshaft. Slacken off the uppermost screw. Leave it in place, screwed in a few turns.

Carefully work the flywheel and carrier plate loose. Use 2 groove-cut chisels. Apply these between the cylinder block and the flywheel and carrier plate.

Hold the flywheel and carrier plate and remove the final screw.

Install the engine in a stand

Use mounting stand see 9992520 , fixture see 9995297 and screw set see 9989721 .

Scheme 1015

REMOVE (B6XX4S)

Scheme 1016

REMOVE (B6XX4S)

Scheme 1017

REMOVE (B6XX4T)

Scheme 1018

REMOVE (B6XX4T)

Scheme 1019

REMOVE (B6XX4T)

Special tools

see 9995112

see 9995662

see 9995663

see 9995675

see 9995677

Note. To remove the transmission, see TRANSMISSION - REMOVAL, REPLACEMENT AND INSTALLATION .

see SEALING MICRO-ENCLOSED SCREWS

Scheme 1020

Install the following items

1. ignition coils Torque: M6 10 Nm
2. fuel rails/fuel injectors Torque: M6 10 Nm
3. the sensor Torque: M6 10 Nm
4. cover crankcase ventilation Torque: M6 10 Nm
5. lifting eyes Torque: M10 50 Nm

Scheme 1021

1. Oil trap Torque: M6 10 Nm
2. water pipe Torque: M7 17 Nm
3. the thermostat housing Torque: M6 10 Nm

Scheme 1022

Install the cable harness.

Torque: M6

10 Nm

Scheme 1023

Install the generator. See GENERATOR

Scheme 1024

Install intake manifold. See INDUCTION PIPE

Scheme 1025

see 9995297 see 9992520 see 9989721

Install carrier plate. See CARRIER PLATE

Scheme 1026

Install transmission. See TRANSMISSION (B6324S, TF-80SC; 2007-2010) or TRANSMISSION (B6324S, TF-80SC AWD; 2007-2010)

Scheme 1027

Install the following items

1. radiator hose
2. front auxiliary unit console, see «AUXILIARY BRACKETS»(ref-476775-S38061557382012060500000)
3. console transmission
4. AC-console
5. water pipe Torque: M6 10 Nm

Install the engine. See ENGINE, INSTALLING

Drain the engine oil. See OIL FILTER

Remove the engine. See ENGINE, REMOVAL

Remove the following components

1. radiator hose
2. front auxiliary unit console
3. console transmission
4. AC-console
5. water pipe

Scheme 1028

Remove drive flange plate/flywheel. See CARRIER PLATE

Install the following items

1. see «9992520»(ref-460875-S32052658872012033000000)
2. see «9995297»(ref-460875-S21331165912012033000000)
3. see «9989721»(ref-460875-S01561744442012033000000)

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

Special tools

see 9992520

see 9995297

see 9989721

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

HINT: Remove the lower screws (these are difficult to access) between the transmission and engine before the engine/transmission unit is placed on a suitable surface. Remove the remaining screws. Carefully remove the transmission. For automatic transmissions remove the converter screws.

Remove the carrier plate. See: REMOVAL .

PLACE THE ENGINE IN A STAND

Use see 9992520 , see 9995297 and see 9989721 .

drain the oil. See: OIL/OIL FILTER, REPLACING .

EXPOSING THE ENGINE

Remove

1. engine cable harness, note the position of the connectors
2. manifold, see: «EXHAUST MANIFOLD/GASKET, CYLINDER 1, 3, 5 AND 7 (BANK 1), REPLACING»(ref-476768-S21666858272012060500000)
3. manifold, see: «EXHAUST MANIFOLD/GASKET, CYLINDER 2, 4, 6 AND 8 (BANK 2), REPLACING»(ref-476768-S03971953522012060500000)
4. the alternator, see: «GENERATOR (GEN), REPLACEMENT»(ref-476783-S17337479832012060500000) .

GEAR HOUSING, RECONDITIONING

Special tools T9995670 PLIERS (REMOVING VALVES/CAMSHAFT COVER) B4184-B6304 Tool number: T9995670 Tool description: PLIERS (REMOVING VALVES/CAMSHAFT COVER) B4184-B6304 Tool boards: T9997315 PULLER Tool number: T9997315 Tool description: PULLER Tool boards: T9997258 ANVIL BLOCK Tool number: T9997258 Tool description: ANVIL BLOCK Tool boards: T9997259 PULLER Tool number: T9997259 Tool description: PULLER Tool boards: T9997317 ANVIL BLOCK Tool number: T9997317 Tool description: ANVIL BLOCK Tool boards: T9997329 ANVIL BLOCK Tool number: T9997329 Tool description: ANVIL BLOCK Tool boards: T9997318 PRESS TOOL Tool number: T9997318 Tool description: PRESS TOOL Tool boards: T9997328 PRESS TOOL Tool number: T9997328 Tool description: PRESS TOOL Tool boards: T9997319 PRESS TOOL Tool number: T9997319 Tool description: PRESS TOOL Tool boards: T9997320 PRESS TOOL Tool number: T9997320 Tool description: PRESS TOOL Tool boards: T9997337 ANVIL BLOCK Tool number: T9997337 Tool description: ANVIL BLOCK Tool boards: T9997322 ANVIL BLOCK Tool number: T9997322 Tool description: ANVIL BLOCK Tool boards: T9997321 PRESS TOOL Tool number: T9997321 Tool description: PRESS TOOL Tool boards: T9997324 PRESS TOOL Tool number: T9997324 Tool description: PRESS TOOL Tool boards: T9997323 PRESS TOOL Tool number: T9997323 Tool description: PRESS TOOL Tool boards: T9997325 PRESS TOOL Tool number: T9997325 Tool description: PRESS TOOL Tool boards: T9997326 PRESS TOOL Tool number: T9997326 Tool description: PRESS TOOL Tool boards: T9997327 PRESS TOOL Tool number: T9997327 Tool description: PRESS TOOL Tool boards: T9997316 PUNCH Tool number: T9997316 Tool description: DRIFT Tool boards: T9997260 DRIFT Tool number: T9997260 Tool description: DRIFT Tool boards

Scheme 1029

Scheme 1030

Scheme 1031

Scheme 1032

Scheme 1033

Scheme 1034

Scheme 1035

Scheme 1036

Scheme 1037

Scheme 1038

Scheme 1039

Scheme 1040

Scheme 1041

Scheme 1042

Scheme 1043

Remove the Transmission Accessory Drive Component, rear. See: REAR END ACCESSORY DRIVE

Scheme 1044

Scheme 1045

Scheme 1046

see 9995670

Scheme 1047

see 9997315

Scheme 1048

Scheme 1049

Make sure that new component is installed.

Scheme 1050

see 9997258

Scheme 1051

see 9997259

Scheme 1052

Scheme 1053

Scheme 1054

Note. This step requires considerable force.

see 9997317

see 9997329

Scheme 1055

Remove the snap rings on both sides.

Scheme 1056

see 9997318 see 9997328 see 9997319

Scheme 1057

see 9997320 see 9997337 see 9997319

This procedure releases the cam drive shaft's pulley.

Scheme 1058

see 9997322 see 9997337 see 9997321

Scheme 1059

Note. do not release the transportation protection ring in the bearing

Note. Make sure that a new component is installed.

see 9997324 see 9997337 see 9997323

Scheme 1060

see 9997325 see 9997337 see 9997326

Scheme 1061

Use: Isopropanol, 1161721

Scheme 1062

Use: Isopropanol, 1161721

Use: Metal adhesive, 1161722

Scheme 1063

see 9997328 see 9997318 see 9997327

Scheme 1064

see 9997317 see 9997329

Chain wheel. See TIGHTENING TORQUE

Scheme 1065

see 9997316

Scheme 1066

Scheme 1067

Note. Make sure that the mating faces are clean and free of foreign material.

Note. The component must be installed within 5 minutes of applying the sealant.

Use: Liquid gasket, 1161771

Scheme 1068

Gear housing. See TIGHTENING TORQUE

Scheme 1069

Note. Make sure that the mating faces are clean and free of foreign material.

1. Use: Liquid gasket, 1161771

Scheme 1070

Note. Use a new seal.

see 9997260

see 9997258

Intermediate shaft, alternator side. See TIGHTENING TORQUE

M6. See TIGHTENING TORQUE

REAR END ACCESSORY DRIVE

Special tools 999 5670 Pliers (removing valve/camshaft cover) B4184-B6304 Tool number: 999 5670 Tool description: Pliers (removing valve/camshaft cover) B4184-B6304 Tool boards: 21 999 7315 Puller Tool number: 999 7315 Tool description: Puller Tool boards: 21 999 7316 Drift Tool number: 999 7316 Tool description: Drift Tool boards: 21