Engine, Repair Using Short-block
 Remove, Disconnect Remove engine with transmission - see corresponding operation. Remove attaching parts and transmission - see corresponding operations.
 Install, Connect Attach engine to Engine Overhaul Stand KM-412 with Adapters KM-412-3. | 
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Remove, Disconnect Place collecting basin underneath and drain engine oil. Release and remove toothed belt - see operation "Toothed Belt, Remove and Install". Remove camshaft housing cover. Unbolt camshaft pulley from camshaft. For this counterhold camshaft at special lug between 1st and 2nd cylinders (see illus.). | 
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Remove, Disconnect Remove toothed belt tension roller and rear toothed belt cover (arrows). Remove coolant pump, inductive pulse pick-up, starter and line and flange for crankcase ventilation. Tension thrust plate with KM-632-A (1) and secure with Clamp Set KM-526-A (2). Remove thrust plate with clutch disc.
 Important! If the clutch assembly is reused, mark thrust plate relative to flywheel. | 
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Remove, Disconnect Lock flywheel via starter ring gear using KM-652 and remove (see illus. I). Loosen cylinder head bolts in a spiral pattern from outside inwards, first 1/4 and then 1/2 turn (see illus. II). Unscrew cylinder head bolts and lift camshaft housing from cylinder head. Remove cam followers, thrust pieces and hydraulic valve lifters and lay aside so that they cannot get mixed up. Lift cylinder head from cylinder block. Remove centring sleeves (1, see illus. III) from cylinder block using pliers. Unbolt oil pan from cylinder block. Remove oil intake pipe and oil pump. | 
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 Clean Clean all removed parts and sealing surfaces.
 Inspect Check all removed parts for damage and wear, replace if necessary. Check cylinder head for plane surface - see operation "Cylinder Head, Check for Plane Surface". | 
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 Assemble Assemble new short block. Emboss engine number in cylinder block with embossing drift. Drive centring sleeves into cylinder block with KM-427 up to stop. | 
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Install, Connect Install flywheel with new bolts and lock with KM-652 via starter ring gear (see illus. I).
 Torque - Angle Method Flywheel to crankshaft - 35 Nm / 26 lbf. ft. + 30 ° + 15 ° 1) . Use new bolts.
Install, Connect Fit clutch assembly - see operation "Clutch Disc, Thrust Plate, Clutch Thrust Bearing and / or Release Lever, Remove and Install" in group "K". Install oil pump. Slide protective sleeve for KM-417 onto crankshaft journal. Install oil pump with new seal and new seal ring (see illus. II, arrows). Lightly coat seal lip of seal ring with silicone grease (white) before installation. Install oil intake pipe with new seal ring. | 
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1) Re-cut thread in crankshaft.
 Tighten (Torque)
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Oil pump to cylinder block |
- 10 Nm / 7 lbf. ft. |
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Oil intake pipe to oil pump |
- 8 Nm / 6 lbf. ft. 1) |
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Oil intake pipe bracket to cylinder block |
- 8 Nm / 6 lbf. ft. |
1) Bolts must be re-cut before re-use and inserted after being coated with bolt locking compound (red). Installation time max. 10 min.
Install, Connect Coat joints of sealing surface on cylinder block (arrows) with adhesive sealing compound (black). Install oil pan with new gasket. Screw in oil drain plug with new seal ring.
Tighten (Torque)
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Oil pan to cylinder block |
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- 10 Nm / 7 lbf. ft. 1) |
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Oil pan to transmission casing (aluminium oil pan) |
M8 |
- 20 Nm / 15 lbf. ft. |
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M10 |
- 40 Nm / 29.5 lbf. ft. |
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Oil drain plug to oil pan (sheet metal oil pan) |
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- 55 Nm / 41 lbf. ft. |
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Oil drain bolt to oil pan (hex bolt) |
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- 45 Nm / 33 lbf. ft. |
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Aluminium oil pan |
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Oil drain bolt to oil pan (inner Torx bolt) |
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- 14 Nm / 10 lbf. ft. |
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Aluminium oil pan |
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1) Bolts must be re-cut before re-use and inserted after being coated with bolt locking compound (red). Installation time max. 10 min. | 
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Install, Connect Install new cylinder head gasket with identification OBEN/TOP on top and pointing towards engine timing side. Place cylinder head on cylinder block - 1st cylinder 60 ° before "TDC". | 
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Install, Connect Insert hydraulic valve play compensator, thrust pieces and rocker arm (see illus. I). Coat sliding surfaces of camshaft and rocker arm with MoS 2 lubricating paste (grey). Coat sealing surface between cylinder head and camshaft housing uniformly with surface sealant (green). Place camshaft housing onto cylinder head. Insert new cylinder head bolts and tighten in a spiral pattern from the inside outwards in four stages (see illus. II). Install rear toothed belt cover and camshaft pulley. Counterhold camshaft at lug between 1st and 2nd cylinders (see illus. III).
Torque - Angle Method Cylinder head to cylinder block - 25 Nm / 18 lbf. ft. + 60 ° + 60 ° + 60 °
Tighten (Torque)
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Rear toothed belt cover to camshaft and oil pump housings |
- 6 Nm / 4 lbf. ft. |
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Camshaft pulley to camshaft |
- 45 Nm / 33 lbf. ft. |
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Install, Connect Replace seal ring for coolant pump and lightly coat sealing surface with silicone grease (white). Insert coolant pump and tighten fastening bolts. Install toothed belt tension roller. Observe installation position. Insert lug (1) of tension roller base plate in bore hole (2) of oil pump housing. Install toothed belt and perform basic adjustment of toothed belt tension roller. Adjust timing - see corresponding operations. Install inductive pulse pick-up - if present. | 
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Install flange and line for crankcase ventilation (see illus.). Install starter.
Tighten (Torque)
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Inductive pulse pick-up bracket to oil pump housing |
- 10 Nm / 7 lbf. ft. |
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Starter to cylinder block |
- 25 Nm / 18 lbf. ft. |
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Install, Connect Install camshaft housing cover with new gasket. Coat seal ring for oil filter cartridge with engine oil and tighten oil filter cartridge hand-tight. Fill with engine oil up to mark "MAX" on dipstick. Attach transmission to cylinder block.
Tighten (Torque)
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Camshaft housing cover to camshaft housing |
8 Nm / 6 lbf. ft. |
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Transmission to cylinder block |
60 Nm / 44 lbf. ft. |
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Install, Connect | 
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Remove engine from Engine Overhaul Stand KM-412. Install attaching parts - see corresponding operations. Install engine with transmission - see corresponding operation. |
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