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 (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 (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
    • Notes
    • Preparation
    • Removing The Oil Filter / Oil Pan
    • Removing The Oil Pump Suction Pipe
    • Checking Markings
    • Removing The Pistons From The Cylinder Block
    • Removing The Piston Nozzles
    • Removing The Screwed Joint From The Intermediate Section
    • Separating The Intermediate Section From The Cylinder Block
    • Cleaning
  • 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
• 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
• Crank Mechanism (B6294S2; B6294T; 2002-2006)
  • Assembling The Crank Mechanism
  • Disassembling The Crankshaft Assembly
  • Measuring The Crankshaft Assembly
• Cylinder Block (B5254T2; 2004)
  • Cylinder Block, Measurement
    • Measuring The Cylinder Bore
    • Checking For Wear
    • Classification Marking
• Cylinder Block (B6284T; B6294S; 2000-2001)
  • Cylinder Block
    • Measuring The Cylinder Bore
    • Checking For Wear
    • Classification Marking
• Cylinder Block (B6284T; B6304S3; 1999)
  • Cylinder Block
• Cylinder Block (B6294S2; B6294T; 2002-2006)
  • Cylinder Block
• Cylinder Head (B5254T2; 2004)
  • Installing The Cylinder Head
    • Notes
    • Tightening Torque
    • Aligning The Crankshaft
    • Installing The Cylinder Head
    • Installing Tappets And Camshafts
    • Applying Liquid Gasket
    • Installing The Camshaft Covers
    • Installing The Front Camshaft Seal
    • Installing The Rear Camshaft Seal
    • Securing The Camshafts
  • Measuring And Reconditioning The Cylinder Head
    • Notes
    • Removing Tappets
    • Removing Valves
    • Removing Valve Stem Seals
    • Checking The Cylinder Head
    • Checking For Wear In The Valve Guides
    • Checking The Height Of The Valve Stems
    • Installing Valve Stem Seals
    • Installing Valve Springs
  • Removing The Cylinder Head
    • Notes
    • Removing The Camshaft Pulleys
    • Removing The Camshaft Cover
    • Removing The Cylinder Head
• Cylinder Head (B5254T2; 2005-2006)
  • Cylinder Head, Dismantling/Assembling
    • Notes
    • Removing Tappets
    • Removing Valves
    • Removing Valve Stem Seals
    • Checking The Cylinder Head
    • Checking For Wear In The Valve Guides
    • Installing Valve Stem Seals
    • Installing The Valve / Valve Springs
  • Cylinder Head, Installing
    • Notes
    • Aligning The Crankshaft
    • Installing The Cylinder Head
    • Installing Valve Lifters And Camshafts
    • Applying Liquid Gasket
    • Installing The Camshaft Covers
    • Cleaning
    • Installing The Front Camshaft Seal
    • Installing The Rear Camshaft Seal
    • Securing The Camshafts
  • Cylinder Head, Removing
    • Notes
    • Removing The Camshaft Pulleys
    • Removing The Camshaft Cover
    • Removing The Cylinder Head
• Cylinder Head (B6284T; B6294S; 2000-2001)
  • Installing The Cylinder Head
    • Notes
    • Tightening Torque
    • Aligning The Crankshaft
    • Installing The Cylinder Head
    • Installing Tappets And Camshafts
    • Applying Liquid Gasket
    • Installing The Camshaft Covers
    • Installing The Front Camshaft Seal
    • Installing The Rear Camshaft Seal
    • Securing The Camshafts
  • Measuring And Reconditioning The Cylinder Head
    • Notes
    • Removing Valve Lifters From The Cylinder Head
    • Removing Valves
    • Removing Valve Stem Seals
    • Checking The Cylinder Head
    • Checking For Wear In The Valve Guides
    • Checking The Vertical Position Of The Valve Stem
    • Installing Valve Stem Seals
    • Installing Valve Springs
  • Removing The Cylinder Head
    • Notes
    • Removing The Camshaft Variable Valve Timing Unit / Timing Belt Pulley
    • Removing The Camshaft Cover
    • Removing The Cylinder Head
• Cylinder Head (B6284T; B6304S3; 1999)
  • Installing The Cylinder Head
    • Notes
    • Tightening Torques
    • Aligning The Crankshaft
    • Installing The Cylinder Head
    • Installing Valve Lifters And Camshafts
    • Applying Liquid Gasket
    • Installing The Camshaft Covers
    • Installing The Front Camshaft Seal
    • Installing The Rear Camshaft Seal
    • Securing The Camshafts
  • Measuring And Reconditioning The Cylinder Head
    • Notes
    • Removing Valve Lifters From The Cylinder Head
    • Removing Valves
    • Removing Valve Stem Seals
    • Checking The Cylinder Head
    • Checking For Wear In The Valve Guides
    • Checking The Vertical Position Of The Valve Stem
    • Installing Valve Stem Seals
    • Installing Valve Springs
  • Removing The Cylinder Head
• Cylinder Head (B6294S2; B6294T; 2002-2006)
  • Installing The Cylinder Head
  • Measuring And Reconditioning The Cylinder Head
  • Removing The Cylinder Head
• 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
• Gearbox (B6284T; 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
  • 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
• Gearbox (B6294S2; 2002-2006)
  • Belt Drive, Assembling
  • Dismantling The Belt Drive
• Gearbox (B6294T; 2002-2006)
  • 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
  • Dismantling The Belt Drive
• General (B5254T2; 2004-2006)
  • Engine Block, Installing Components
    • Notes
    • Installing Engine Block Components
  • Engine Body, Exposing
    • Notes
    • Removing The Gearbox
    • Removing The Flywheel And Carrier Plate
    • Exposing The Engine
    • Pressure Plate / Clutch Driven Plate, Replacing
      • Notes
      • Removal
      • Installation
  • Sealing Micro-Enclosed Screws
    • Notes
    • Sealant
    • Engine Intake Side
    • Engine Exhaust Side
    • Rear Of Engine
    • Engine Front
  • Caulking
• General (B6284T; 1999-2001)
  • Engine Block, Installing Components
  • Exposing The Engine Body
    • Notes
    • Removing The Transmission
    • Removing The Flywheel And Carrier Plate
    • Exposing The Engine
    • Pressure Plate / Clutch Driven Plate, Replacing
      • Notes
      • Removal
      • Installation
  • Sealing Micro-Enclosed Screws
• General (B6294S; 2000-2001)
  • Engine Block, Installing Components
  • Exposing The Engine Body
  • Sealing Micro-Enclosed Screws
• General (B6294S2; B6294T; 2002-2006)
  • Engine Block, Installing Components
  • Exposing The Engine Body
  • Sealing Micro-Enclosed Screws
• General (B6304S3; 1999)
  • Engine Block, Installing Components
  • Exposing The Engine Body
  • Sealing Micro-Enclosed Screws
  • Caulking
• 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
      • Notes
      • Removal
      • Installation
  • 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
• 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