Cylinder Block, Remounting of Components
Cylinder Block, Remounting Of Components
Special tools: 5039, 5367, 5996, 9696
Install oil pump
Lubricate pump rotors liberally.
Place rotors in pump housing.
Locate seal in groove in joint flange.
Tighten to 11 Nm (8 ft.lb).
NOTE: Position outer rotor as indicated by marking.
Fit oil pump shaft seal
Use assembly tool 5361.
Note: Face of seal should normally be flush with chamfered edge in housing. However, if shaft end shows signs of wear, seal may be located approx. 2 mm further in.
Install drive pulley
Use counterhold 5039.
Rotate pulley to align with flat on shaft.
Tighten center bolt to 20 Nm (15 ft.lb) and through a further 60°.
Install relief valve
Use new gasket.
Insert plunger with rounded end facing inwards. Install spring and plug.
Tighten to 40 Nm (30 ft.lb).
Install coolant pump
Place gasket on block.
Position top of pump housing flush with top of block.
Tighten pump housing.
Install return pipe and drain cock
Place gasket on pipe.
Secure pipe to pump housing and block.
Tighten drain cock.
Note: Ensure that cock is closed.
Install oil pressure switch
Use new seal.
Install new oil filter
Coat face of seal with oil.
Screw home filter by hand until seal makes firm contact with block.
Turn a further 1/2-3/4 turn.
Install oil dipstick tube
Use new seal on tube.
Insert dipstick.
Note: Check dipstick seal and replace as required.
Install knock sensor
Ensure that connector socket is horizontal and facing towards front.
Tighten to 25 Nm (18 ft.lb).
Assemble balance shaft housings
Install rear bearing shells.
Position shells flush with joint surfaces.
Apply liquid sealing compound
Apply compound (P/N 1 161 059-9) to housing half not provided with guide sleeves.
Note: Excess sealing compound must be removed from oilways and bearing surfaces prior to assembly.
Lubricate balance shaft bearings
Oil bearing shells in both housing halves.
Note: Lubricant must not be allowed to come in contact with liquid sealing compound or joint faces.
Place balance shaft in position
Place shaft in housing half to which liquid sealing compound has been applied.
Install rear sealing plate
Fit new 0-ring in plate groove.
Position seal in housing half with balance shaft.
Reassemble balance shaft housing
Tighten bolted joint all around to ensure halves are pulled together evenly.
Tighten to 5 Nm (3.5 ft.lb). Ensure that shaft turns freely in housing.
Inspect balance shaft housing mountings on cylinder block
Check that mountings are perfectly clean.
Place 0-rings in position
Place 0-rings in grooves around housing oilways.
Fix 0-rings in position by packing grooves with grease and lubricate housing joint faces with thin coating of grease.
Install balance shaft housings
Ensure housing is replaced evenly on front and rear mountings. Max. permissible deviation between mounting faces with reference to block is 1 mm (0.04 in).
Tighten bolts alternately in diagonal pattern. Tighten each bolt by max. 1/2 turn at a time.
Tighten bolts to 20 Nm (15 ft.lb).
Slacken and retighten to 10 Nm (7.5 ft.lb) and through a further 90°.
Note: Check that shaft turns freely in housing throughout tightening procedure.
Tighten bolted joint between housing halves
Tighten to 8 Nm (6 ft.lb).
Check end float of balance shaft
Measure end float using dial gauge mounted on magnetic stand 9696.
Install balance shaft seals
Use assembly tool 5996.
Grease seal.
Press seal lightly into shaft housing, using tool 5996. Use center bolt together with tool to press home fully.
Note: Face of seal should normally be flush with chamfered edge in housing. However, if shaft end shows signs of wear, seal may be located approx. 2 mm further in.