Removal and Replacement: Overview
Overview
I
II
III
IV
Part I
1 - 25 Nm
2 - Generator
3 - 25 Nm
4 - Relay lever
5 - Spacer
^ Note installed position
6 - Pulley
^ For ribbed belt
7 - Tensioning element
^ For ribbed belt
8 - Bracket
^ For Generator, ribbed belt tensioning element, viscous fan clutch and power steering pump
9 - 45 Nm
^ Observe tightening sequence
10 - 45 Nm
11 - Power steering pump
12 - Banjo bolt
^ Tighten to 30 Nm
13 - Oil seal
^ Always replace
14 - Pressure line
15 - Pulley
^ For power steering pump
16 - Bracket
^ For tensioning element
17 - Pulley
^ For viscous fan clutch
18 - Viscous fan clutch
19 - 30 Nm
Part II
1 - Toothed belt cover - upper part
2 - Toothed belt
^ Mark direction of rotation before removing
^ Check for wear
^ Do not kink
3 - 20 Nm plus an additional 1/8 turn (45°)
4 - Tensioning roller
5 - 100 Nm
6 - 25 Nm
7 - Camshaft sprocket
8 - Hub
^ With sensor wheel
^ Use counter-holder T10051 to loosen and tighten
^ To remove, use pulling fixture T10052
9 - 10 Nm
10 - Rear toothed belt cover
11 - Grommet
12 - Idler roller
13 - Coolant pump
14 - Crankshaft toothed belt sprocket
15 - 120 Nm plus an additional 1/4 turn (90°)
^ Always replace
^ Use counter support 3415 to loosen and tighten
^ Do not additionally oil or grease threads or collar
^ Additional rotation can occur in several stages
16 - 15 Nm
17 - 20 Nm
18 - Toothed belt cover - lower part
19 - Belt pulley/harmonic balancer
^ Only possible to install in one position - holes are offset
20 - 10 Nm plus an additional 1/4 turn (90°)
21 - Toothed belt cover - center part
Part III
1 - Cylinder head cover
^ Before installing, clean contact surface of cylinder head with clean shop rag
2 - To turbocharger
3 - Pressure regulator valve
^ For crankcase ventilation
4 - Cap
^ Replace seal if damaged
5 - Sealing sleeve
^ Replace if damaged
6 - 10 Nm
^ First, fasten all bolts hand-tight
7 - Seal for cylinder head cover
^ Only replace together with cylinder head cover
^ Before installing, seal contact surfaces with sealant AMV 174 004 01.
8 - 20 Nm
9 - Lifting eye
10 - 10 Nm
11 - Central harness connector
^ For Pump-Injector unit
12 - From brake booster
13 - Tandem pump
^ For fuel and vacuum supply
14 - 25 Nm
15 - Supply hose
^ White or with white markings
^ Ensure seated tightly
^ Secure with spring-type clips
16 - Return hose
^ Blue or with blue marking
^ Ensure seated tightly
^ Secure with spring-type clips
17 - Seal
^ Always replace
18 - Bolt
19 - Bracket
^ For fuel filter
20 - Cylinder head
^ After replacing replace entire amount of coolant
21 - Cylinder head gasket
^ Replace
^ Observe identification
^ After replacing replace entire amount of coolant
22 - Camshaft Position (CMP) sensor -G40-
^ For camshaft position
^ To remove, remove grommet from rear of toothed belt cover
23 - Cylinder head bolt
^ Replace
24 - Pump-Injector unit
Part IV
1 - 45 Nm
2 - Hood
3 - Bracket
^ For vacuum reservoir and Wastegate bypass regulator valve -N75-
4 - Cylinder block
^ With balance shaft module
5 - Bracket
^ For fuel filter
6 - Bolt
7 - 10 Nm
8 - Seal
^ Replace
9 - Oil filter bracket
10 - 15 Nm plus an additional 1/4 turn (90°)
^ Replace
^ First, fasten upper left and lower right bolts, then tighten all four bolts in a diagonal sequence
11 - Engine speed (RPM) sensor
12 - Connection
^ For thermostat
13 - 15 Nm
14 - O-ring
^ Replace
15 - Coolant thermostat
16 - 45 Nm
17 - Bracket
^ For Generator, ribbed belt tensioning element, viscous fan clutch and power steering pump
18 - Oil pan
^ Clean sealing surface before installing
^ Install with silicone sealant D 176 404 A2.
19 - 15 Nm
^ Use hex ball socket T10058 to remove and install two rear bolts on transmission
Tightening sequence, bracket to cylinder block
- Place bracket on cylinder block (observe sleeve between compact bracket and cylinder block).
- Tighten compact bracket in tightening sequence as follows:
1 - Tighten bolt - A -, 45 Nm
2 - Tighten bolt - B -, 45 Nm
3 - Tighten bolt - C -, 45 Nm
4 - Tighten bolt - D -, 45 Nm
5 - Tighten bolt - E -, 45 Nm
6 - Tighten bolt - F -, 45 Nm