Engine (211348)

Special Service Tool(s)

Universal flange holding wrench
205-072 (15-030A)

Oil seal installer and aligner
303-055 (21-017A)

Mounting bracket
303-435-06 (21-031B)

Remover and installer, vibration damper
303-130 (21-076)

Mounting plate
303-435-11 (21-146C)

Installer, camshaft pulley
303-458 (21-192)

Adapter, oil seal installation
303-458-01 (21-192-01)

Installer, crankshaft rear oil seal
303-460 (21-193A)

Angle gauge, bolt tightening
303-174 (21-540)

Radiator hose clamp remover/installer
303-397 (24-003)

General Equipment

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≥ Assembly stand ≥

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Materials

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≥ Lubricant, O-rings ≥ ESD-M97B49-A ≥ ≥

√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¥

≥ Lubricant, spark ≥ ESE-M1244-A (Never ≥ ≥

≥ plugs ≥ Seeze) ≥ ≥

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≥ Sealer, flywheel ≥ SDM-M4G9107-A ≥ ≥

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≥ Sealer, oil ≥ SM-4G-4644-AA/AB ≥ ≥

≥ /coolant passages ≥ ≥ ≥

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≥ Lubricant, ≥ SQM-2C9002-AA ≥ ≥

≥ camshaft bearings ≥ ≥ ≥

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≥ Sealer, cylinder ≥ WSK-M4G320-A ≥ ≥

≥ block ≥ ≥ ≥

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≥ Engine oil ≥ WSS-M2C912-A1 ≥ ≥

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Assembly

1.

CAUTION:

Only use a plastic scraper when removing old gasket material.

Thoroughly clean all mating faces and reusable parts and check them for damage.

2.

Note:
Do not remove the blanking plugs or alignment dowels unless they are being renewed.

Reseal the oil passage blanking plugs as necessary.

z

Use oil/coolant passage sealer.

µ

3.

Note:
The main bearings are precision fit parts. Check the bearing clearance. For additional
information, refer to

«Section 303-00»

.

Install the upper main bearing shells and the thrust half ring.

1

Thrust half ring

2

Upper main bearing shells

z

Coat the main bearing shells and thrust half ring with engine oil.

µ

4.

CAUTION:

Avoid damage to the crankshaft bearing journal surfaces.

Install the crankshaft.

µ

5.

Note:
Press the crankshaft back before inserting the main bearing shells.

Note:
Align the oil bores on the bearing shells and the cylinder block.

Note:
Align the assembly lug on the bearing shells with the mating face of the cylinder block.

Install the lower main bearing shells.

1

Crankshaft thrust main bearing shell.

2

Lower main bearing shells.

z

Coat the main bearing shells and the thrust main bearing shell with engine oil.

6.

Clean the lower and upper cylinder block mating faces before beginning assembly.

µ

7.

Note:
The bolts must be tightened within 4 minutes of applying the sealer.

Apply a bead of sealer to the cylinder block.

z

Apply cylinder block sealer on both sides up to a distance of 6 mm from the rear
crankshaft bore.

z

Apply a 3 mm bead of sealer to the indicated areas.

z

Apply a 1 mm bead of sealer to the indicated areas.

µ

8.

CAUTION:

Check the installation position of all locating dowels in the lower crankcase.

Note:
The bolts must be tightened within 4 minutes of applying the sealer.

Note:
Do not lubricate the lower crankcase bolts.

Note:
Tightening sequence.

Attach the lower crankcase to the cylinder block.

z

Push the crankshaft rearward and insert the thrust half ring.

µ

9.

CAUTION:

Bolts 1 to 16 are torque-to-yield bolts and must be renewed.

Note:
Different torques.

Note:
Tightening sequence.

Tighten the bolts in four stages.

z

Bolts 1 - 8, 25 Nm

z

Bolts 9 - 16, 40 Nm

z

Bolts 1 - 16, 90 degrees

z

Bolts 17 - 22, 25 Nm

z

Check that the crankshaft rotates freely.

10.

Remove any protruding sealer residue.

11.

CAUTION:

Protect the surfaces of the crankshaft bearing journals and the cylinder bore from
damage.

Place the crankshaft with the main bearing journal in the BDC position.

12.

Note:
Install the piston with the arrow pointing to the front of the engine.

Compress the piston rings and install the piston and the connecting rod.

z

Coat all piston components with engine oil.

µ

13.

CAUTION:

When assembling the connecting rods and connecting rod bearing caps, it is imperative
that the bearing slots and lugs are located on the same side of the connecting rod.

CAUTION:

The connecting rod bolts are torque-to-yield bolts and must be renewed.

Fit the connecting rod bearing cap to the appropriate connecting rod and alternately tighten the
bolts in three stages as indicated.

z

Stage 1: 23 Nm

z

Stage 2: 43 Nm

z

Stage 3: 90 degrees

14.

Check the connecting rod axial clearance. For additional information, refer to

«Section 303-00»

.

15.

Rotate the crankshaft to check that it can turn freely.

µ

16.

Note:
Tightening sequence.

Install the oil pump.

µ

17.

Install the oil pan baffle.

z

Tighten the nuts in two stages.

z

Stage 1: 5 Nm

z

Stage 2: 45 degrees

µ

18.

Note:
Apply O-ring lubricant to the O-ring before installation.

Install the oil pick-up pipe retaining nut.

z

Tighten the nut in two stages.

z

Stage 1: 5 Nm

z

Stage 2: 45 degrees

µ

19.

Install the oil pick-up pipe retaining bolts.

µ

20.

Note:
Install a new oil separator gasket.

Install the oil separator.

µ

21.

Install the bracket for the power steering pump.

z

Align the bracket with the locating sleeves.

µ

22.

Note:
Install a new cylinder head gasket.

Note:
Left-hand and right-hand cylinder head gaskets are not interchangeable.

Note:
Install a new cylinder head bolts with washers.

Install the left-hand cylinder head.

z

Align the cylinder head with the locating dowels.

z

Tighten the bolts in the sequence shown in two stages..

z

Stage 1: 40 Nm

z

Stage 2: 90 degrees

µ

23.

Loosen the left-hand cylinder head bolts.

z

Loosen the bolts in the sequence shown one turn.

µ

24.

Tighten the left-hand cylinder head bolts in the sequence shown in three stages..

z

Stage 1: 40 Nm

z

Stage 2: 90 degrees

z

Stage 3: 90 degrees

µ

25.

Note:
Install new cylinder head gasket.

Note:
Left-hand and right-hand cylinder head gaskets are not interchangeable.

Note:
Install new cylinder head bolts with washers.

Install the right-hand cylinder head.

z

Align the cylinder head with the locating dowels.

z

Tighten the bolts in the sequence shown in two stages.

z

Stage 1: 40 Nm

z

Stage 2: 90 degrees

µ

26.

Loosen the right-hand cylinder head bolts.

z

Loosen the bolts in the sequence shwon one turn.

µ

27.

Tighten the right-hand cylinder head bolts in the sequence shown in three stages.

z

Stage 1: 40 Nm

z

Stage 2: 90 degrees

z

Stage 3: 90 degrees

28.

Check all the camshafts in accordance with the specifications. For additional information, refer
to

«Section 303-00»

.

µ

29.

Position the crankshaft for installation of the left-hand timing chain.

z

Install the washer and the bolt on the crankshaft pulley/vibration damper.

z

Turn the crankshaft clockwise until the Woodruff key is in the 11 o'clock position.

30.

Install the valve tappets.

z

Coat the tappets with camshaft bearing lubricant prior to installation.

µ

31.

Install the camshafts on the left-hand cylinder head and align them with the top edge of the
cylinder head.

1

Position the marking on the intake camshaft to the 9 o'clock position.

2

Position the marking on the exhaust camshaft to the 12 o'clock position.

µ

32.

CAUTION:

Install the thrust bearing caps (1L and 5L) last.

Note:
Do not tighten the bolts.

Install the bearing caps of the left-hand camshaft.

z

Use camshaft bearing lubricant.

µ

33.

Install the camshafts on the right-hand cylinder head and align them with the top edge of the
cylinder head.

1

Position the mark on the exhaust camshaft to the 12 o'clock position.

2

Position the mark on the intake camshaft to the 3 o'clock position.

µ

34.

CAUTION:

Install the thrust bearing caps (1R and 5R) last.

Note:
Do not tighten the bolts at this stage.

Install the bearing caps of the right-hand camshaft.

z

Use camshaft bearing lubricant.

35.

Remove the crankshaft pulley/vibration damper bolt.

µ

36.

Note:
The copper links of the timing chain and the marks on the timing chain sprockets must line up.

Install the left-hand timing chain.

1

Install the timing chain guide (black material).

2

Push on the crankshaft timing chain sprocket. The mark for adjusting the valve timing
must face towards the front.

3

Install the timing chain.

µ

37.

Install the left-hand timing chain tensioner and left-hand timing chain guide.

1

Install the timing chain guide.

2

Install the pre-tensioned timing chain tensioner and the adapter plate (if removed).

3

Tighten the timing chain by applying pressure to the timing chain guide, and pull the wire
out of the timing chain tensioner.

µ

38.

Note:
The copper links of the timing chain and the marks on the timing chain sprockets must line up.

Install the right-hand timing chain.

1

Install the timing chain guide (beige mounting).

2

Push on the crankshaft timing chain sprocket. The mark for adjustment of the valve timing
must face towards the front.

3

Install the timing chain.

µ

39.

Install the right-hand timing chain tensioner.

1

Install the timing chain guide.

2

Install the pre-tensioned timing chain tensioner and the adapter plate (if removed).

z

Tighten the timing chain by applying pressure to the timing chain guide, and pull the wire
out of the timing chain tensioner.

µ

40.

CAUTION:

Crankshaft Woodruff key at 11 o'clock position.

Install the cam followers on the left-hand cylinder head.

z

Use camshaft bearing lubricant.

µ

41.

Note:
Tightening sequence.

Tighten the bearing caps on the left-hand camshaft.

z

Use thrust bearing caps 1L und 5L to adjust the camshaft end play.

42.

Install the crankshaft pulley/vibration damper bolt.

µ

43.

Position the crankshaft for installation of the right-hand timing chain.

z

Turn the crankshaft clockwise until the Woodruff key is in the 3 o'clock position.

µ

44.

Install the cam followers on the right-hand cylinder head.

z

Use camshaft bearing lubricant.

µ

45.

Note:
Tightening sequence.

Tighten the bearing caps on the right-hand camshaft.

µ

46.

Note:
Install the timing case cover within six minutes after applying the sealer.

Install the CKP sensor pulse ring and apply 6 mm of sealer to the indicated areas.

1

Install the CKP sensor pulse ring in the key groove with the blue paint mark.

2

Apply cylinder block sealer.

z

Indentation towards the front.

µ

47.

Note:
Install a new timing chain cover gasket.

Install the timing chain cover.

z

Tighten the studs in the sequence shown.

µ

48.

Note:
Tightening sequence.

Tighten the remaining timing chain cover bolts and studs.

µ

49.

Note:
Coat the new O-rings with engine oil.

Install the sensors and wiring brackets.

1

CKP sensor

2

CMP sensor.

3

Wiring bracket

4

Wiring bracket

µ

50.

Using the special tool, install the crankshaft front oil seal.

z

Lubricate the outer ring and the sealing lip of the oil seal with engine oil.

z

Draw in the crankshaft front oil seal using the special tool and the washer of the
crankshaft pulley/vibration damper bolt.

µ

51.

Using the special tool, install the crankshaft pulley/vibration damper.

µ

52.

Note:
Tightening sequence.

Using the special tool, install the crankshaft pulley/vibration damper.

z

Seal off the Woodruff key in the crankshaft pulley/vibration damper with silicone sealer
and cylinder block sealer.

z

Tighten the bolt in four stages.

z

Stage 1: 120 Nm

z

Stage 2: Turn the bolt back a full turn.

z

Stage 3: 50 Nm

z

Stage 4: 90 degrees

µ

53.

Note:
Do not tighten the power steering pump bracket retaining bolts and studs at this stage.

Install the power steering pump and bracket.

µ

54.

Note:

The longer 84 mm retaining bolts should be tightened first.

Tighten the 84 mm power steering pump retaining bolts.

µ

55.

Tighten the power steering pump retaining nuts.

µ

56.

Note:
The indentation on the pulley must face towards the front of the engine.

Attach the pulley to the power steering pump.

µ

57.

Install the camshaft oil seal carrier.

z

Insert a new gasket and align the carrier on the locating dowels.

µ

58.

CAUTION:

Do not damage the running surface of the camshaft.

Using the special tools, install the camshaft oil seal.

z

Lubricate the outside of the oil seal with engine oil.

µ

59.

Using the special tool, install the camshaft pulley.

z

Heat the belt pulley, locate it in position and draw it on as far as it will go.

µ

60.

Apply sealer to the cylinder head mating face intersections.

z

Use a silicone gasket and cylinder block sealer.

61.

Install the spark plugs - tightening torque 15 Nm.

z

Use spark plug lubricant.

µ

62.

Note:

Install new valve cover gaskets.

Note:
Tightening sequence

Install the valve covers.

µ

63.

Install the wiring harness retaining plate and the left-hand engine lifting eye.

µ

64.

Apply sealer to the mating face intersections.

z

Use a silicone gasket and cylinder block sealer.

z

Apply a 10 mm wide strip of sealer to the points shown.

µ

65.

Note:
Location of the studs.

Note:
Tightening sequence

Note:
Install the oil pan within six minutes of applying the sealer.

Install the oil pan with a new gasket.

µ

66.

Install the oil pan heat shields.

µ

67.

Install the oil cooler and the oil pressure switch.

1

Install the oil cooler retaining bolt.

2

Apply sealer to the thread of the oil pressure switch and install the switch.

z

Coat the oil cooler seal, the O-ring and the oil filter seal with engine oil.

z

Use oil/coolant passage sealer.

µ

68.

Note:
Tightening sequence.

Install the left-hand exhaust manifold and catalytic converter with a new gasket.

µ

69.

Install the oil filter.

µ

70.

Install the generator bracket.

µ

71.

Install the generator.

1

Generator bolts

2

Bracket bolt

µ

72.

Using the special tools, install the crankshaft rear oil seal.

z

Lubricate the outer ring and sealing lip with engine oil.

µ

73.

Install the flywheel.

1

Install the adapter plate.

2

Apply sealer to the bolts and tighten them working diagonally.

z

Use flywheel sealer.

z

Using the special tool 205-072, hold the crankshaft by the vibration damper.

µ

74.

Note:
Tightening sequence

Install the coolant pump.

1

Tighten the new bolts in two stages.

z

Stage 1: 10 Nm

z

Stage 2: 90 degrees

2

Connect the coolant hose.

3

Connect the coolant hose.

µ

75.

Install the coolant connecting pipe between the cylinder heads.

z

Use new O-rings and coat them with O-ring lubricant.

µ

76.

Attach the positive crankcase ventilation hose and valve.

1

Attach the positive crankcase ventilation hose and valve.

2

Tighten the nut.

µ

77.

Install the water pump drive belt.

z

Rotate the belt tensioner clockwise to release the tension on the belt.

µ

78.

Attach the coolant distribution pipe, the engine lifting eye and the oil dipstick.

1

Install the engine lifting eye.

2

Install the dipstick with a new oiled O-ring.

3

Screw on the nuts.

µ

79.

Using the special tool, install the thermostat housing with the coolant hoses.

µ

80.

Note:
Install new gaskets with the locating lugs facing downwards.

Note:
Tightening sequence

Install the lower the intake manifold.

µ

81.

Install the fuel injection system wiring harness.

1

ECT sensor plug

2

DPFE sensor plug

3

Fuel injector connector

µ

82.

Connect the plugs.

1

Oil pressure switch

2

CKP sensor

3

CMP sensor

z

Clip the wiring harness in place.

83.

Connect the HO2S sensor.

µ

84.

Note:
Install new gaskets with the locating lugs pointing downwards.

Note:
Tightening sequence.

Install the upper part of the intake manifold.

µ

85.

Connect the hoses and plugs

1

Plug to the TP sensor

2

Positive crankcase ventilation hose

3

Plug to the IAC valve

µ

86.

Connect the vacuum hoses.

1

To the upper part of the intake manifold.

2

To the electronic vacuum regulator

3

To the fuel pressure regulator

4

To the DPFE

5

To the EGR valve

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87.

Install the electronic ignition (EI) coil.

z

Connect the electrical connectors.

µ

88.

Install the IMRC actuator.

1

Install the retaining bolts.

2

Connect the IMRC electrical connector.

µ

89.

Install the IMRC cable.

µ

90.

Install the wiring harness and connect the electrical conectors.

1

Attach the wiring rail.

2

Generator cable

3

DPFE sensor plug

4

Electronic vacuum regulator plug

5

ECT sensor to coolant connection pipe

µ

91.

Remove the special tools.

µ

92.

Install the intermediate shaft retaining bracket.

µ

93.

Note:
Tightening sequence.

Install the right-hand exhaust manifold with a new gasket.

µ

94.

Connect the EGR pipe to the EGR valve.

1

Screw on the EGR pipe.

2

Connect the hoses to the EGR pipe.

95.

Finishing operations.

z

Fill the engine with engine oil.