Engine number "Letter designation" and "engine number" are located on a sticker -arrow- on the upper toothed belt guard. "Letter designation" And "engine number" are additionally indicated on the engine crankcase near the junction of...
Removing the engine Note: The engine is removed downwards with the gearbox. After installing the engine, it is necessary to reinstall all cable ties that are removed or cut off during dismantling in the same place. Leave the ignition key...
Engine installation Installation in reverse order. Install intermediate plate. For vehicles with manual gearbox Clean input shaft splines, and if clutch disc has already been used clean hub splines, remove any traces of existing corrosion...
Tightening torques Note: The tightening torques apply to lightly greased or oiled, phosphated or oxidized bolts and nuts. Additional lubricants allowed (e.g. motor or gear oils), except graphite-containing. Do not use degreased parts....
Details and assemblies of the supports of the power unit 1. 40 Nm and tighten by 90° (1/4 vol.): replace 2. Engine mount bracket 3. Motor support: with bracket 4. 40 Nm and tighten by 90° (1/4 vol.): replace 5. 20 Nm and tighten by 90° (1/4 vol.): replace 6. 8 Nm 7. Bracket...
Engine disassembly — parts and assemblies Vehicles without air conditioning 1. 150 Nm and tighten by 180° (½ turn): replace; when loosening and tightening, use stop -T10475- Carefully! Risk of engine damage. It is forbidden to turn the crankshaft with the bolt...
Removal and installation of poly V-belt Vehicles without air conditioning To loosen the poly V-belt, turn the tensioner counterclockwise -arrow-. Lock tensioner with locking pin -T10060 A-. Carefully! Only install a used belt in the same direction of travel....
Removal and installation of a poly V-belt tensioner Remove poly V-belt from tensioner. Remove screws -arrows- and remove tensioner -1- for poly V-belt. Installation Installation in reverse order. Install poly V-belt. Torque
Removal and installation of a pulley of a v-ribbed belt of a crankshaft Remove soundproof cover. Remove poly V-belt. Loosen bolt -arrow- using stop -T10475-. Loosen the bolt and remove the crankshaft V-ribbed belt pulley. Carefully! Risk of engine damage. It is forbidden to turn the...
Removal and installation of an arm of a support of the engine Disconnect battery. Remove battery bracket, drain coolant. Loosen clamps -1- and -2- and remove air pipe. Remove the air filter housing. Remove the poly V-belt tensioner. Release hoses from bracket -3-. Remove screw...
Replacing the crankshaft seal on the pulley side Remove toothed belt. Remove crankshaft pulley -1- -arrow-. Carefully! Risk of engine damage. It is forbidden to turn the crankshaft with the crankshaft pulley removed - this can lead to a change in the valve timing....
Parts and assemblies of the cylinder block from the gearbox side Note: For assembly work, secure engine to engine and gearbox stand -VAS 6095-. 1. 60 Nm and tighten by 90° (1/4 vol.): replace 2. Handwheel: Mounting possible in one position only 3. Engine speed sender -G28- 4. 5 Nm 5....
Details and components of the cylinder head Carefully! Do not remove camshafts individually. During the repair, the entire camshaft housing assembly is replaced. 1. Cylinder head gasket: install in the correct position: part number points towards the cylinder...
Removal and installation of cylinder head Note: When installing, fasten all thermal insulation sleeves in their original positions. Remove the camshaft housing. Remove intake manifold. Disconnect electrical connectors. 1. From low oil pressure sender -F378-. 2....
Removal and installation of the camshaft housing Remove coolant pump. Remove the air filter housing. Remove ignition coils. Remove toothed belt from camshafts. Remove high pressure pipe -3-. Disconnect connector -1-. Loosen clamp -2- and detach hose. Disconnect...
Compression test Engine oil temperature not lower than 30°C. The battery voltage is not lower than 12.5 V. Remove the fuel pump control unit fuse from the fuse box. Note: If the fuse is removed, the power supply to the fuel pump control...
Toothed belt drive — parts and assemblies Parts and assemblies of the toothed belt guard 1. Lower part of the toothed belt cover 2. 8 Nm 3. Engine mount bracket 4. Bolt 5. Upper timing belt cover 6. 8 Nm Parts and assemblies - toothed belt 1. Toothed belt:...
Checking the valve timing Loosen clamps -1, 2- and remove air duct. Release the air hoses at the air connection. Disconnect connector -1-. Unlock catches -arrows- and remove air duct. Press the release buttons and disconnect the hose -1- going...
Removing the timing belt from the camshaft Loosen clamps -1, 2- and remove air duct. Release the air hoses at the air connection. Disconnect connector -1-. Unlock catches -arrows- and remove air duct. Press release buttons and detach hose -1-. Unscrew screws...
Installation / adjustment of valve timing Note: Replace screws that are tightened to the specified angle. If the o-ring of the screw plug is damaged, replace the o-ring. Check position "TDC" camshaft and crankshaft. Install camshaft clamp -T10494- on camshaft...
Removal and installation of a gear belt Loosen clamps -1, 2- and remove air duct. Release the air hoses at the air connection. Disconnect connector -1-. Unlock catches -arrows- and remove air duct. Press the release buttons and disconnect the hose -1- going...
Installing / adjusting the timing Note: Replace screws that are tightened to the specified angle. If the o-ring of the screw plug is damaged, replace the o-ring. Check position "TDC" camshaft and crankshaft. The camshaft lock -T10494- is mounted on the...
Parts and assemblies of the valve mechanism 1. Inlet valve: not subject to processing, only grinding is allowed 2. Exhaust valve: not subject to processing, only lapping is allowed 3. Cylinder head 4. Oil scraper cap 5. Valve spring 6. Valve spring plate 7. Valve...
Removal and installation of lip seals Removal and installation of the lip seal of the intake camshaft from the side of the pulleys Remove toothed belt from camshaft pulleys. Remove bolt -1- and remove camshaft gear. Remove oil seal -1- using puller...
Removal and installation of the oil pallet Drain engine oil. Remove oil filter using oil filter wrench -3417-. Remove poly V-belt. Only for vehicles with air conditioning Note: The air conditioner refrigerant circuit will not leak. Do not damage the condenser,...
Removal and installation of the oil pump Disconnect battery. Remove toothed belt. Remove oil pan. Unscrew securing bolts -arrows- and remove tensioner. Remove generator. Remove the crankshaft lip seal from the pulley side. Release screws -1- and -2- for oil...
Engine oil cooling radiator Parts and assemblies of the engine oil cooling radiator 1. Engine oil cooler: after replacement, change the coolant 2. 8 Nm and tighten by 90° (¼ vol.): replace 3. Lip seals/O-rings: replace Removing and installing...
Details and components of the crankcase ventilation system 1. Hose: for crankcase ventilation system 2. Cap: oil separator 3. Oil separator: replace if damaged 4. O-ring: replace; moisten with oil before installation 5. Spigot: ensure the correct mounting position 6. Hose: for...
Removal and installation of an oil separator Remove soundproof cover. Unscrew bolt -arrow- and press coolant bleed pump to one side after switching off. engine -V51-. Disconnect crankcase breather hose -3-. Release -arrow- locks -2- on oil separator cover -1- and...
Removal and installation of oil sensors Removing and installing oil pressure drop sender -F378- Detach canister solenoid valve 1 -N80- -3- from intake manifold and press valve downwards slightly. Disconnect connector -2-. Remove low oil pressure sender -F378-...
Removal and installation of the oil filter housing Drain engine oil. Remove oil filter -arrow- using oil filter wrench -3417-. Installation Fill the oil filter with engine oil and moisten the seal with oil. Tighten oil filter with oil filter wrench -3417-, tightening...