Engine - Overhaul Instructions
- Crank Mechanism (B5254T2; 2004)
- Crank Mechanism, Assembling
- Notes
- Tightening Torque
- Cleaning
- Installing The Piston Cooling Valve And Nozzles
- Classification Of Main Bearings
- Selecting Bearings
- The Intermediate Section
- Tightening The Intermediate Section
- Marking The Connecting Rod (Where Applicable)
- Installing Piston Rings
- Assembling Pistons And Connecting Rods
- Installing The Pistons In The Cylinder Bores
- Tightening The Connecting Rod Cover
- Installing The Oil Pump Suction Pipe
- Installing the oil pan
- Installing The Oil Cooler
- Installing The Rear Crankshaft Seal
- Disassembling The Crankshaft Assembly
- Notes
- Preparation
- Removing The Oil Filter And Oil Pan
- Removing The Suction Pipe From The Oil Pump
- Checking Markings
- New Connecting Rod
- Removing The Pistons From The Cylinder Block
- Removing The Screwed Joint From The Intermediate Section
- Separating The Intermediate Section From The Cylinder Block
- Removing The Piston Cooling Valve And Nozzles
- Cleaning
- Crank Mechanism, Assembling
- Measuring The Crankshaft Assembly
- Notes
- Measuring The Crankshaft
- Check The Out-Of-True Of The Crankshaft
- Removing The Piston Rings
- Checking Piston Ring Axial Clearance
- Checking The Piston Diameter
- Calculating The Running Clearance Of The Piston
- Disassembling Connecting Rods And Pistons
- Checking The Alignment Of The Piston Pins In The Pistons
- Checking The Alignment Of The Piston Pins In The Connecting Rods
- New Connecting Rod
- Checking The Bearing Recess In The Connecting Rod Big End
- Checking The Connecting Rod In A Connecting Rod Aligner
- Crank Mechanism, Assembling
- Crank Mechanism (B5254T2; 2005-2006)
- Crank Mechanism, Assembling
- Notes
- Cleaning
- Installing The Piston Cooling Valve And Nozzles
- Classification Of Main Bearings
- Selecting Bearings
- Applying Liquid Gasket
- Tightening The Intermediate Section
- Marking The Connecting Rod (Where Applicable)
- Selecting Piston
- Installing Piston Rings
- Assembling Pistons And Connecting Rods
- Installing The Main Bearing Shells
- Installing The Pistons In The Cylinder Bores
- Tightening The Connecting Rod Cover
- Installing The Oil Pump Suction Pipe
- Installing The Sump
- Installing The Oil Cooler
- Installing The Rear Crankshaft Seal
- Crankshaft Assembly, Disassembling
- Notes
- Preparation
- Removing The Oil Filter And Oil Pan
- Removing The Suction Pipe From The Oil Pump
- Checking Markings
- New Connecting Rod
- Removing The Pistons From The Cylinder Block
- Check
- Removing The Screwed Joint From The Intermediate Section
- Separating The Intermediate Section From The Cylinder Block
- Removing The Piston Cooling Valve And Nozzles
- Cleaning
- Crank Mechanism, Assembling
- Crank Mechanism (B6284T; B6304S3; 1999)
- Assembling The Crank Mechanism
- Notes
- Tightening Torques
- Cleaning
- Classification Of Main Bearings
- Selecting Bearings
- The Intermediate Section
- Tightening The Intermediate Section
- Marking The Connecting Rod (Where Applicable)
- Installing Piston Rings
- Assembling Pistons And Connecting Rods
- Installing The Pistons In The Cylinder Bores
- Tightening The Connecting Rod Cover
- Installing The Oil Pump Suction Pipe
- Installing The Oil Pan
- Installing The Oil Cooler
- Installing The Rear Crankshaft Seal
- Disassembling The Crank Mechanism
- Measuring The Crankshaft Assembly
- Notes
- Measuring The Crankshaft
- Check The Out-Of-True Of The Crankshaft
- Removing The Piston Rings
- Checking The Axial Clearance Of The Piston Rings
- Checking The Piston Diameter
- Calculating The Running Clearance Of The Piston
- Disassembling Connecting Rods And Pistons
- Checking The Alignment Of The Piston Pins In The Pistons
- Checking The Alignment Of The Piston Pins In The Connecting Rods
- Checking The Bearing Recess In The Connecting Rod Big End
- Checking The Connecting Rod In A Connecting Rod Aligner
- Assembling The Crank Mechanism
- Crank Mechanism (B6284T; B6294S; 2000-2001)
- Assembling The Crank Mechanism
- Notes
- Tightening Torques
- Cleaning
- Installing The Piston Cooling Valve And Nozzles
- Classification Of Main Bearings
- Selecting Bearings
- The Intermediate Section
- Tightening The Intermediate Section
- Marking The Connecting Rod (Where Applicable)
- Installing Piston Rings
- Assembling Pistons And Connecting Rods
- Installing The Pistons In The Cylinder Bores
- Tightening The Connecting Rod Cover
- Installing The Oil Pump Suction Pipe
- Installing The Oil Pan
- Installing The Oil Cooler
- Installing The Rear Crankshaft Seal
- Disassembling The Crankshaft Assembly
- Notes
- Preparation
- Removing The Oil Filter And Oil Pan
- Removing The Suction Pipe From The Oil Pump
- Checking Markings
- New Connecting Rod
- Removing The Pistons From The Cylinder Block
- Removing The Screwed Joint From The Intermediate Section
- Separating The Intermediate Section From The Cylinder Block
- Removing The Piston Cooling Valve And Nozzles
- Cleaning
- Measuring The Crankshaft Assembly
- Notes
- Measuring The Crankshaft
- Check The Out-Of-True Of The Crankshaft
- Removing The Piston Rings
- Checking Piston Ring Axial Clearance
- Checking The Piston Diameter
- Calculating The Running Clearance Of The Piston
- Disassembling Connecting Rods And Pistons
- Checking The Alignment Of The Piston Pins In The Pistons
- Checking The Alignment Of The Piston Pins In The Connecting Rods
- New Connecting Rod
- Checking The Bearing Recess In The Connecting Rod Big End
- Checking The Connecting Rod In A Connecting Rod Aligner
- Assembling The Crank Mechanism
- Crank Mechanism (B6294S2; B6294T; 2002-2006)
- Cylinder Block (B5254T2; 2004)
- Cylinder Block (B6284T; B6294S; 2000-2001)
- Cylinder Block (B6284T; B6304S3; 1999)
- Cylinder Block (B6294S2; B6294T; 2002-2006)
- Cylinder Head (B5254T2; 2004)
- Cylinder Head (B5254T2; 2005-2006)
- Cylinder Head (B6284T; B6294S; 2000-2001)
- Cylinder Head (B6284T; B6304S3; 1999)
- Cylinder Head (B6294S2; B6294T; 2002-2006)
- Gearbox (B6284T; B6304S3; 1999)
- Assembling The Belt Drive
- Notes
- Tightening
- Installing The Thermostat Housing And Water Pump
- Installing The Oil Pump
- Installing The Crankshaft Timing Gear Pulley
- Installing The Tensioner / Damping Unit And The Idler Pulley
- Installing The Camshaft Timing Gear Pulley, B6xx4T
- Installing The Camshaft Timing Gear Pulley, B6xx4S
- Installing The Timing Belt
- Installing The Vibration Damper
- Check
- Dismantling The Belt Drive
- Notes
- Aligning The Engine According To The Marking
- Removing The Vibration Damper
- Removing The Timing Belt
- Installing the tensioner / damping unit
- Removing The Crankshaft Pulley
- Removing The Belt Tensioner And Idler Pulley
- Removing Oil Pump
- Checking The Oil Pump
- Removing The Coolant Pump
- Removing The Thermostat / Thermostat Housing
- Checking The Opening Function Of The Thermostat
- Assembling The Belt Drive
- Gearbox (B6284T; 2000-2001)
- Belt Drive, Assembling
- Dismantling The Belt Drive
- Notes
- Aligning The Engine According To The Marking
- Removing The Vibration Damper
- Removing The Timing Belt
- Removing The Crankshaft Pulley
- Removing The Belt Tensioner And Idler Pulley
- Removing Oil Pump
- Checking The Oil Pump
- Removing the coolant pump
- Removing The Thermostat And Thermostat Housing
- Checking The Opening Function Of The Thermostat
- Gearbox (B6294S; 2000-2001)
- Belt Drive, Assembling
- Notes
- Tightening
- Installing The Thermostat Housing And Water Pump
- Installing The Oil Pump
- Installing The Crankshaft Timing Gear Pulley
- Installing The Idler Pulley And Belt Tensioner
- Checking And Adjusting The Variable Valve Timing Unit
- Installing The Vibration Damper
- Variable Valve Timing Unit, Checking And Adjusting
- Dismantling The Belt Drive
- Belt Drive, Assembling
- Gearbox (B6294S2; 2002-2006)
- Gearbox (B6294T; 2002-2006)
- General (B5254T2; 2004-2006)
- General (B6284T; 1999-2001)
- General (B6294S; 2000-2001)
- General (B6294S2; B6294T; 2002-2006)
- General (B6304S3; 1999)
- Timing Gear (B5254T2; 2005-2006)
- Belt Drive, Assembly
- Notes
- Tightening Torque
- Installing The Water Pump
- Installing The Oil Pump
- Installing Front Crankshaft Seal
- Installing The Crankshaft Timing Gear Pulley
- Installing The Idler Pulley And Belt Tensioner
- Installing The Timing Gear Pulley For The Camshafts
- Installing The Variable Valve Timing (VVT) Unit On The Intake Camshaft
- Finishing
- Installing The Timing Belt
- Adjusting The Timing Belt
- Checking The Markings And Belt Tension
- Installing The Vibration Damper
- Oil Pump / Crankshaft Seal, Front, Replacing
- Belt Drive, Dismantling
- Notes
- Aligning The Engine According To The Marking
- Removing The Vibration Damper
- Removing The Timing Belt
- Removing The Crankshaft Pulley
- Removing The Belt Tensioner And Idler Pulley
- Removing The Oil Pump
- Checking The Oil Pump
- Assembling The Oil Pump
- Removing The Coolant Pump/Timing Belt Cover
- Removing The Thermostat And Thermostat Housing
- Checking The Opening Function Of The Thermostat
- Belt Drive, Assembly
- Transmission (B5254T2; 2004)
- Belt Transmission, Assembly
- Notes
- Tightening Torque
- Installing The Water Pump
- Installing The Oil Pump
- Installing The Crankshaft Timing Gear Pulley
- Installing The Idler Pulley And Belt Tensioner
- Installing The Timing Gear Pulley For The Camshafts
- Installing The Timing Belt
- Installing The Vibration Damper
- Checking The Markings And Belt Tension
- Dismantling The Belt Transmission
- Notes
- Aligning The Engine According To The Marking
- Removing The Vibration Damper
- Removing The Timing Belt
- Removing The Crankshaft Pulley
- Removing The Belt Tensioner And Idler Pulley
- Removing Oil Pump
- Checking The Oil Pump
- Removing The Coolant Pump / Timing Belt Cover
- Removing The Thermostat And Thermostat Housing
- Checking The Opening Function Of The Thermostat
- Belt Transmission, Assembly