Assembly Special Tool(s) | Universal Flange Holding Wrench 205-072 (15-030A) | | Lifting Bracket, Engine 303-122 (21-068A) | | Socket, Cylinder Head Bolt 303-392 (21-167) | | Mounting Stand 303-435 (21-187) | | Mounting Bracket for 303-435 303-435-06 (21-031B) | | Mounting Plate for 303-435-06 303-435-11 (21-146C) | General Equipment Piston ring compressor Straight edge Materials Name Specification Engine oil WSS-M2C912-A1 Sealant WSE-M4G323-A Sealant WSK-M2G349-A4 Assembly | -
Install the crankshaft main bearing shells. | | -
NOTE:The bearing cap numbering starts from the front of the engine, to which the arrows also point. Install the crankshaft. - Lubricate the main bearing journals and bearing shells with clean engine oil.
- Make sure that the cylinder No. 1 is in top dead center (TDC) position.
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NOTE:The grooves in the crankshaft thrust half-washers must be face outwards. Install the crankshaft thrust half-washers. | | -
NOTE:The connecting rod numbering starts from the front of the engine. The arrow on the piston crown points towards the front of the engine. - Lubricate the pistons and cylinder liners with clean engine oil.
- Distribute the piston ring end gaps uniformly around the circumference. This also applies to the elements of the oil scraper ring.
- Using the handle of a hammer, press pistons No. 1 and 4 into the cylinders. The connecting rod bearing journal must be at bottom dead center (BDC).
- Check the bearing shells are clean and dry and install them in the associated connecting rods and bearing caps.
- Turn the crankshaft through 180 degrees and install pistons No. 2 and 3.
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CAUTION:Install new connecting rod retaining bolts. NOTE:The connecting rods and connecting rod bearing caps have the same numbering. Install the crankshaft bearing caps. - Lubricate the bearing shells and journals with clean engine oil.
- Tighten the crankshaft bearing cap retaining bolts in two stages.
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Install the oil pan baffle. | | -
Install the timing chain guide, timing chain tensioner arm and the crankshaft sprocket. | | -
NOTE:The mark on the crankshaft timing sprocket and the single colored link of the timing chain must line up. Install the timing chain. | | -
CAUTION:Only install the oil pump together with the crankshaft pulley. CAUTION:When installing a new oil pump, do not remove the crankshaft pulley or the assembly clip before installation. NOTE:Install a new oil pump gasket. NOTE:A new oil pump is supplied as an assembly with a crankshaft front seal and a crankshaft pulley. NOTE:Do not tighten the oil pump retaining bolts at this stage. Install the oil pump assembly. | | -
Using the special tool, tighten the crankshaft pulley retaining bolt. - Remove the assembly clip.
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NOTE:The oil pump sealing flange must be within ± 0.20 mm of the cylinder block bottom sealing flanges. Using a suitable straight edge, align the oil pump to the cylinder block sealing flanges. | | -
NOTE:Install new pre-sealed bolts in positions 1 and 3. Tighten the oil pump retaining bolts. - Tighten the bolts in the sequence shown.
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NOTE:Make sure that the O-ring seal is correctly seated. Install the oil pump pick-up pipe. | | -
CAUTION:Do not remove the installation sleeve before installation. NOTE:Install a new crankshaft rear seal carrier. NOTE:A new rear seal carrier is supplied preassembled on an installation sleeve. NOTE:Do not touch the dust lip and the sealing lip. NOTE:The sealing lip must be free of oil. NOTE:Make sure that the dowel pins are correctly seated. Install the crankshaft rear seal carrier. | | -
CAUTION:Install the oil pan gasket within five minutes of applying the sealant. Apply sealant to the cylinder block joints. | | -
NOTE:Do not fully tighten the oil pan retaining bolts at this stage. Using a suitable straight edge, align the oil pan to the cylinder block. - Maximum oil pan face underflush: 0.25 mm.
- Maximum oil pan face protrusion: 0.10 mm.
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Tighten the oil pan retaining bolts in the sequence shown (stage 1). | | -
Tighten the oil pan retaining bolts in the sequence shown (stage 2). | | -
Install the adaptor plate. | | -
Install the water pump pulley. | | -
NOTE:Install a new cylinder head gasket. NOTE:Install new cylinder head bolts. NOTE:Guide the timing chain through the cylinder head and secure it to the cylinder head. Using the special tool, install the cylinder head. - Tighten the cylinder head bolts in the sequence shown in four stages.
- Stage 1: Tighten bolts 1 through 10 to 40 Nm.
- Stage 2: Tighten the front two bolts (M8) to 15 Nm.
- Stage 3: Tighten the front two bolts (M8) bolts to 45 degrees.
- Stage 4: Tighten bolts 1 through 10 to 120 degrees.
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NOTE:The camshaft sprocket timing mark must be in the 12 o’clock position. NOTE:The camshaft sprocket timing mark and the marked links of the timing chain must line up. Install the timing chain to the camshaft sprocket. - The camshaft sprocket timing mark must be at the 12 o’clock position with cylinder No. 1 at TDC.
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Using the special tool, install the camshaft sprocket. | | -
Install the oil level indicator and tube. - Apply sealant to base of the oil level indicator tube.
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Install the timing chain hydraulic tensioner. | | -
NOTE:Install a new coolant flow control housing gasket if necessary. Install the coolant flow control housing. | | -
NOTE:Install a new oil filter adaptor gasket. Install the oil filter adaptor. | | -
Install a new oil filter. | | -
Install the crankshaft position (CKP) sensor. | | -
Install the oil pressure switch. | | -
Install the knock sensor (KS). | | -
NOTE:Install a new valve cover gasket if necessary. Install the valve cover. | | -
NOTE:Install a new intake manifold gasket if necessary. Install the intake manifold. | | -
Connect the camshaft position (CMP) sensor and engine coolant temperature (ECT) sensor electrical connectors. | | -
Connect the positive crankcase ventilation (PCV) hose to the intake manifold. | | -
Install the generator retaining bracket. | | -
Install the engine front mount bracket. | | -
Install the special tool. | | -
Remove the special tools. | | -
NOTE:Install a new exhaust manifold gasket and new exhaust manifold retaining nuts. Install the exhaust manifold. - Tighten the retaining nuts in the sequence shown in two stages.
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Install the exhaust manifold heat shield. | | |