Engine, Repair Using Short-block
 Remove, Disconnect Remove engine with transmission - see operation "Engine with Transmission, Remove and Install". Install engine with Adapter KM-412-11-B onto Engine Overhaul Stand KM-412. Remove transmission and clutch. Remove attaching parts. | 
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Drain engine oil and remove oil filter cartridge. 15 DT and X 15 DT, unbolt oil cooler from cylinder block. Unbolt bracket for exhaust pipe from cylinder block. Remove oil pan, oil baffle and oil intake pipe. | 
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Remove, Disconnect Release and remove V-belt. Remove alternator with vacuum pump (1). Unbolt alternator bracket from cylinder block. Remove upper toothed belt panelling. Place engine to 1st cylinder TDC and insert TDC positioning bolts. Lock flywheel with KM-652 and remove crankshaft pulley (2). Unbolt lower toothed belt panelling (3). | 
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Remove, Disconnect Loosen fastening of toothed belt tension roller and detach spring (15 D, 15 DT, X 15 DT) or stirrup (17 D, X 17 D). Remove toothed belt. Remove toothed belt tension roller. Illustration shows toothed belt tension roller on 15 D, 15 DT and X 15 DT. | 
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Illustration shows toothed belt tension roller on 17 D, X 17 D. | 
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Remove, Disconnect Remove coolant pump. Remove coolant duct guide. Remove toothed belt drive gear. For this, use Remover KM-161-B.
 Important! Ensure that the feather key does not get lost. | 
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Remove, Disconnect Unbolt toothed belt gear from oil pump. For this, place socket wrench on housing bolts and lock toothed belt gear. | 
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Remove, Disconnect Unscrew injection pump drive gear and detach with KM-651-A (1). Remove feather key (wedge). Remove camshaft pulley. Unscrew toothed belt guide roller. Remove front plate. Unscrew oil pump cover and remove with oil pump. Unscrew oil dipstick guide tube from cylinder head and pull out of cylinder block. Remove water pipe hose from thermostat housing and for 15 D remove pipe from water outlet port. Remove water outlet port. Unbolt oil pressure line and oil return line from cylinder block (15 DT, X 15 DT). Remove injection lines from injection pump and injection nozzles. | 
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Remove, Disconnect Remove cylinder head cover. Loosen cylinder head bolts in illustrated sequence with KM-134-A and remove. Lift cylinder head from cylinder block.
 Clean Clean sealing surface at cylinder head. | 
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 Inspect Check cylinder head for warp - see operation "Cylinder Head/ Cylinder Block, Attaching Surfaces, Check for Plane Surface".
Remove, Disconnect Remove starter. Unscrew injection pump and injection pump bracket from cylinder head (see illus.). | 
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Assemble new short block.
 Install, Connect Emboss engine number in cylinder block with number punch. | 
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Install, Connect Install oil pump - see operation "Oil Pump, Remove and Install". Coat new seal ring for oil intake pipe with silicone grease (white) and insert. Fit oil intake pipe. Install oil baffle plate - 26 Nm / 19 lbf. ft. | 
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Clean Clean sealing surface at oil pan.
Install, Connect Coat joints of sealing surface on cylinder block with adhesive sealing compound (black) (see illus. I). Fit oil pan with new seal.
 Tighten (Torque) Oil pan to cylinder block - 10 Nm / 7 lbf. ft.
Install, Connect Insert fitting sleeves for cylinder head and transmission in cylinder block. Select cylinder head gasket - see operation "Piston Projection, Check". Select cylinder head gasket according to measured (average) value. Note identification (arrows) on cylinder head gasket. Position cylinder head gasket with "OBEN/TOP" mark up and towards timing side of engine. | 
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Install, Connect Place cylinder head on cylinder block - 1st cylinder at TDC. Tighten cylinder head bolts with KM-134-A and KM-470-B in a spiral manner, from inside outwards, in 3 stages. Use new cylinder head bolts!
 Torque - Angle Method Cylinder head to cylinder block - 40 Nm / 29.5 lbf. ft. + 60 ° to 75 ° + 60 ° to 75 °
Install, Connect | 
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Install cylinder head cover with new gasket. Insert coolant duct guide in cylinder block. Install coolant pump with new gasket.
Tighten (Torque)
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Cylinder head cover to cylinder head |
- 10 Nm / 7 lbf. ft |
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Coolant pump to cylinder block |
- 24 Nm / 18 lbf. ft. |
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Install, Connect Install injection pump. Connect coolant hoses to injection pump.
Tighten (Torque)
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Injection pump to cylinder block |
- 25 Nm / 18 lbf. ft |
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Injection pump bracket to cylinder block |
- 45 Nm / 33 lbf. ft |
Install, Connect |
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Install front plate. Install camshaft pulley - note installation position!
Tighten (Torque)
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Front plate to cylinder head/cylinder block |
- 10 Nm / 7 lbf. ft |
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Camshaft pulley to camshaft |
- 14 Nm / 10 lbf. ft. |
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Install, Connect Install injection pump drive gear and insert lock screw (arrow). Install toothed belt tension roller and toothed belt guide roller.
Tighten (Torque)
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Injection pump drive gear to injection pump |
- 64 Nm / 47 lbf. ft |
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Toothed belt guide roller to cylinder block |
- 80 Nm / 59 lbf. ft |
 Adjust | 
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Make the following adjustments: operations "Timing, Adjust", "Toothed Belt, Install", "Start of Supply at Fuel Injection Pump, Check and Adjust".
Install, Connect Install injection lines at injection nozzle and install injection pump - 25 Nm / 18 lbf. ft. Connect return line. | 
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Install, Connect Attach water outlet connection to cylinder block. Connect coolant hose to thermostat housing. Fasten coolant pipe at cylinder block (see illus.). | 
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Install, Connect 15 DT and X 15 DT: Screw oil pressure line with hollow bolt and new seal rings to cylinder block. Slide oil return hose onto oil return connection.
Tighten (Torque) Oil pressure line to cylinder block - 15 Nm / 11 lbf. ft. | 
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Install, Connect Screw bracket for alternator and exhaust pipe to cylinder block. Install alternator and vacuum pump. Connect oil return hose (2) to vacuum pump. Screw oil pressure line (1) to vacuum pump. Use new gaskets. Position V-belt and tension. Press oil dipstick guide tube with new seal ring in cylinder block and screw to cylinder head.
Install, Connect | 
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For 15 DT and X 15 DT: Coat seal ring of oil cooler with silicone grease (white) and tighten oil cooler on cylinder block to be handtight. Screw banjo bolt into oil cooler and tighten oil cooler.
Tighten (Torque)
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Oil cooler to cylinder block (hollow bolt) |
30 Nm / 22 lbf. ft |
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Oil cooler to cylinder block (M 10) |
30 Nm / 22 lbf. ft |
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Install, Connect Attach coolant hoses to oil cooler. Coat seal ring of oil filter cartridge with engine oil and install oil filter cartridge. Insert new guide bearing into crankshaft by hand. Install starter. Install clutch and transmission - see operation "Clutch Disc, Thrust Plate, Clutch Thrust Bearing and / or Release Lever, Remove and Install" in group "K". | 
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Remove, Disconnect Remove engine from Engine Overhaul Stand KM-412 and remove adapter.
Install, Connect Install engine with transmission - see operation "Engine with Transmission, Remove and Install". |
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