RECOMMENDED TOOLS
[9] Fywheel setting rod 0188- X
[16] Tool for fitting sealing ring (-).0188-AJ
[43] PR.0516.AO Balance shaft adjustment spacers
[44] Balance shaft positioning gauge (-).0190.D
[45] Balance shaft positioning gauge flange (-).0190.E
REMOVAL SERVICE POINTS
1.Remove The lower casing.
2.Remove the lower oil gauge guide.
3.Remove the upper oil sump.
4.Remove the front sealing panel (104).
5.Remove the oil pump (111) and its chain (108).
6.Remove the key (109).
7.Remove the gear wheel (110).
8.Remove the balancing shafts housing.
INSTALLATION SERVICE POINTS
1.Install the tool [9].
2.Install the adjustment 2 spacers [43].
3.Position the blind holes "n" of the balance shafts upwards.
4.Introduce the 5 mm diameter pins of the tool [44] into the blind holes "n".
5.Install the tool clamp [45] on the tool [44].
6.Gently tighten the screw of the tool [45].
7.Refit the balance shaft housing (25).
8.Engage the balance shaft housing (25) on its centring pins.
9.Remove the tool bearing cap positioning tool kit MB996219 [45], [44].
10.Remove the tool the engine flywheel peg [9].
11.Screw the 8 screws (26) in place.
12.Tighten the bolt (26) to temporary to torque of 10 N·m in the order shown.
13.Tighten the bolt (26) to angle of 60 ± 5° in the order shown.
14.Install the seal (27) (new).
15.Install the pinion (28).
16.Install the key (29).
17.Install the chain (32)
18.Install the oil pump (31)
19.Screw the screws (30) in place (respect the marks made at the time of removal).
20.Tighten the bolt (30) to temporary of hand.
21.Tighten the bolt (30) to torque of 16 ± 30 N·m
22.Put a bead of sealing paste (index E10) onto the sealing plate (104).
23.Install sealing plate (104)
24.Tighten the bolt (103) to torque of 14 ± 1 N·m
25.Install the sealing plate fitted with its fitting cone.
26.Position the sealing grommet (35); Using tool [16].
27.Remove tool [16].
28.Remove the fitting cone.
29.Apply a bead of sealing paste (index E10) to the upper oil sump.
30.Install the upper oil sump (37).
31.The 20 bolts (36) (respect the marks made at the time of removal).
32.The lower oil gauge guide (38).
33.The bolts (39).
34.Tighten the bolt (39) to 9 ± 1 N·m.
35.Bolt (36) tightening sequence:
36.Pre-tighten to 10 N·m (In the order shown).
37.Tightening torque 16 ± 3 N·m (In the order shown).
38.Install the lower oil sump (40).
39.Bolt (41) tightening sequence:
40.Pre-tightening to 10 N·m (In the order shown).
41.Tighten to 16 ± 3 N·m (In the order shown).
TORQUE SPECIFICATIONS
Item
Tightening torque
Alternator
Accessory mounting bracket bolts
20 ± 2 N·m
Alternator bolts
41 ± 4 N·m
Alternator rear support bolts
40 ± 4 N·m
Tensioner roller bolt
43 ± 6 N·m
Tensioner roller bolt
30 ± 3 N·m
Flywheel
Flywheel bolts
15 ± 1 N·m → 47 ± 4 N·m
Fuel injection pipe assembly
coolant outlet housing bolts
8 ± 1 N·m
High-pressure fuel pump bolt
22 ± 2 N·m
Diesel injector fixing clamp bolt
5 ± 1 N·m → 130° ± 5°
Hi-pressure fuel pipe / injectors bolt
22 ± 2 N·m → 25 ± 2 N·m
Hi-pressure fuel pipe clamp bolt
8 ± 2 N·m
High-pressure fuel injection commnrail
18 ± 2 N·m
Intake manifold
Oil cooler and filter assembly mounting nut
16 ± 3 N·m
Oil sediment bowl
8.5 ± 3 N·m
Intake manifold
9 ± 1 N·m
Turbocharger assembly
Turbocharger fixing bolt
25 ± 2 N·m
Turbocharger bracket bolt
30 ± 3 N·m
Turbocharger lubrication hollow bolt
27.5 ± 3 N·m
Exhaust gas recycling duct
10 ± 1 N·m
Exhaust gas recycling valve
10 ± 1 N·m
Cylinder head cover
Accessories drive pulley bolt
Pre-tighten to 70 ± 25 N·m, then carry out an angular tightening of 82 ± 3°
Cylinder head cover bolt
10 ± 1 N·m
Camshaft position sensor bolt
6 ± 1 N·m
Timing belt
Camshaft pulley screw bolt
20 ± 5 N·m → 60 ± 5°
Guide roller screw bolt
43 ± 4 N·m
Engine mounting bolt
60 ± 5 N·m
Engine mounting bolt
80 ± 5 N·m
Coolant pump fixing bolts
10 ± 1 N·m
Tensioner roller screw
25 ± 2 N·m
Drive pulley
70 ± 7 N·m
Cylinder head
Glow plugs
10 ± 1 N·m
Cylinder head bolt
Pre-tighten to 22 ± 2 N·m, then tighten to 60 ± 5 N·m
Un tighten by 1 turn
Tighten to 60 ± 5 N·m
Angular tightening of 220 ± 5°
Timing belt guide roller
Pre-tighten to 15 N·m, then tighten to 43 ± 4 N·m
Timing belt tensioner roller
250 ± 30 N·m
RH engine mounting
Pre-tighten the 4 screws to 10 N·m
Tighten the 8 diameter screw to 20 ± 2 N·m
Tighten the 10 diameter screws to 45 ± 2 N·m
Cylinder head
Cylinder head bolt
Pre-tighten to 22 ± 2 N·m, then tighten to 60 ± 5 N·m
Un tighten by 1 turn
Tighten to 60 ± 5 N·m
Angular tightening of 220 ± 5°
Camshaft bearing cover
Tighten the studs to 10 ± 1 N·m
Pre-tighten the 28 6 diameter screws to 5 N·m
Tighten the 28 6 diameter screws to 10 ± 1 N·m
Timing chain tensioner bolt
7 ± 1 N·m
Camshaft bearing cap bolt
10 ± 1 N·m
Oil pan and oil pump
Balance shaft housing bolt
10 N·m → 60 ± 5°
Oil pump bolts
16 ± 3 N·m
Sealing plate bolt
14 ± 1 N·m
Lower oil gauge guide bolts
9 ± 1 N·m
Upper oil sump bolts
10 N·m → 16 ± 3 N·m
Piston and connecting rod
Piston base jet bolts
10 ± 1 N·m
Crankshaft bearing cap bolts
25 ± 2 N·m → 60 ± 5°
Con-rod screw bolts
20 ± 2 N·m → 48 ± 5°
