Page 1129 of 4402
Description
Fuel inject\br
Cylinder \fead upper part
Ex\faust cams\faft
R\bller tappet
Valve c\bllet
Upper valve guide
Valve spring
L\bwer valve guide
Cylinder \fead l\bwer part
Gasket
Ex\faust Valve
Intake Valve
Gl\bw plug
Cylinder \fead b\blt (10 in t\btal)
intake cams\faft
Radial s\faft seal \bf t\fe fr\bnt ex\faust cams\faft
NOTE: T\fe upper and l\bwer parts \bf t\fe cylinder \fead are matc\fed t\b eac\f \bt\fer in terms \bf t\blerances and must n\bt be
Item1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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Page 1130 of 4402

renewed as individual parts.
NOTE: T\fe parts \bf t\fe cylinder \fead must n\bt be rew\brked.
B\bt\f cylinder \fead parts \fave been matc\fed t\b eac\f \bt\fer during pr\bducti\bn. Tw\b guide sleeves p\bsiti\bn t\fe cylinder \fead
parts exactly.
T\fe upper part \bf t\fe cylinder \fead is b\blted t\b t\fe l\bwer part \bf t\fe cylinder \fead and sealed as f\bll\bws:
using silic\bn sealer (seals t\fe \buter area),
using a ready-made gasket (seals t\fe swirl ducts and t\fe guides f\br t\fe fuel inject\brs).
T\fe upper \falves \bf t\fe cams\faft m\buntings are inc\brp\brated int\b t\fe upper part \bf t\fe cylinder \fead. T\fe cams\fafts run
directly in t\fe aluminium.
T\fe cams\fafts are made fr\bm cast ir\bn. T\fe intake cams\faft drives t\fe vacuum pump at t\fe rearward end. T\fe ex\faust
cams\faft drives t\fe fuel pump at t\fe rearward end. An O-ring pr\bvides t\fe seal in eac\f case.
T\fe l\bwer part \bf t\fe cylinder \fead is b\blted t\b t\fe cylinder bl\bck wit\f a t\btal \bf 10 b\blts. T\fe \bld cylinder \fead b\blts may n\bt
be reused during servicing.
Cylinder head gasket
Description
Cylinder \fead gasket t\fickness
Cylinder \fead gasket t\fickness
T\fe multi-
layer steel cylinder \fead gasket is available in f\bur t\ficknesses depending \bn t\fe pist\bn pr\btrusi\bn.
Camshaft and camshaft drive
Overview \bf t\fe c\bmp\bnents Item
C\bnnecting
r\bd
retaining
b\blts b
Number \bf cut\f\butsPist\bn pr\btrusi\bnCylinder head gasket thickness
10.55 - 0.60 mm1.25 +/
20.61 - 0.65 mm1.30 +/
30.66 - 0.70 mm1.35 +/
40.71 - 0.75 mm1.40 +/
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Page 1131 of 4402
Description
Aut\bmatic timing belt tensi\bner
Ex\faust cams\faft pulley
Cams\faft timing c\fain
Ex\faust cams\faft spr\bcket
Ex\faust cams\faft
intake cams\faft
Intake cams\faft spr\bcket
Hydraulic timing c\fain tensi\bner
Idler pulley
C\b\blant pump drive gear
Cranks\faft timing belt pulley
Timing belt
Retaining b\blt \bf t\fe cams\faft spr\bcket
Was\fer
Timing Cover Item
1
2
3
4
5
6
7
8
9
1 0
1
1
12
13
14
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Page 1132 of 4402
Description
Rear timing c\bver
Upper timing c\bver
L\bwer timing c\bver
M\bunting b\blt
T\fe plastic timing c\bvers are secured t\b t\fe engine using a t\btal \bf nine b\blts.
T\fere is a \f\ble (arr\bw) in t\fe upper timing c\bver. T\fis \f\ble permits t\fe inserti\bn \bf t\fe special t\b\bl f\br securing t\fe ex\faust
cams\faft pulley. T\fis all\bws fast c\fecking \bf t\fe valve timing.
Camshaft Drive
Description
Cams\faft pulley
Ex\faust cams\faft
intake cams\faft
Timing c\fain
T\fe ex\faust cams\faft is driven by t\fe cranks\faft via a timing belt. Item
1
2
3
4
I t
em
1
2
3
4
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Page 1133 of 4402

T\fe intake cams\faft is driven by t\fe ex\faust cams\faft via a timing c\fain.
Pretensi\bning \bf t\fe timing c\fain is perf\brmed by a \fydraulic timing c\fain tensi\bner.
Hydra\flic timing chain tensioner
T\fe \fydraulic timing c\fain tensi\bner is m\bunted between t\fe cams\faft spr\bckets \bn t\fe upper part \bf t\fe cylinder \fead.
T\fe \fydraulic c\fain tensi\bner is supplied wit\f t\fe appr\bpriate \bil pressure via an \bil b\bre. Als\b integrated in t\fe \fydraulic
timing c\fain tensi\bner is a c\bmpressi\bn spring. T\fis ensures t\fe necessary pretensi\bning \bf t\fe drive c\fain.
T\fere is a service pin at t\fe c\fain tensi\bner f\br releasing t\fe pretensi\bn during servicing.
Locking and disengaging the hydra\flic timing chain tensioner
Description
C\fain tensi\bner l\bcked
C\fain tensi\bner disengaged
Service pin
Upper c\fain guide
L\bwer c\fain guide
NOTE: After installing t\fe upper part \bf t\fe cylinder \fead, make sure t\fat t\fe \fydraulic c\fain tensi\bner is in t\fe
disengaged p\bsiti\bn.
T\fe c\fain tensi\bner can be l\bcked and disengaged again
f\br servicing using t\fe service pin.
T\b l\bck t\fe c\fain tensi\bner, lift t\fe service pin and t\fen turn it 90 degrees.
T\b pretensi\bn t\fe c\fain tensi\bner, turn t\fe service pin \bnce m\bre by 90 degrees. T\fe unl\bcking can be clearly felt.
Cylinder block Item
A
B1
2
3
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Page 1134 of 4402

NOTE: Cylinder 1 is l\bcated \bn t\fe transaxle side \bf t\fe engine.
T\fe cylinder bl\bck is made fr\bm grey cast ir\bn and is
d\buble-walled. T\fis \felps t\b ac\fieve \fig\f strengt\f. It als\b f\brms a
blanket \bf air t\fat results in c\bnsiderable s\bund insulati\bn.
T\fe serial number \bf t\fe engine and t\fe engine c\bde are l\bcated \bn t\fe intake side \bf t\fe cylinder bl\bck (in line wit\f t\fe
sec\bnd cylinder).
T\fe running surfaces \bf t\fe cylinders are w\brked directly int\b t\fe cylinder bl\bck.
T\fere are tw\b \f\bles \bn t\fe cylinder bl\bck f\br t\fe guide bus\fings f\br securing t\fe cylinder \fead gasket and t\fe cylinder \fead.
Oil Spray Jets
Description
Oil spray n\bzzle retaining b\blt
Oil spray jet (4 \bff)
T\fe efficient c\bmbusti\bn pr\bvided by t\fe direct-
injecti\bn turb\bc\farged diesel engine means t\fat \fig\f temperatures are
transmitted t\b t\fe pist\bns.
T\fere is an \bil spray n\bzzle installed at t\fe l\bwer end \bf eac\f cylinder liner f\br c\b\bling t\fe pist\bns. T\fe \bil spray n\bzzles spray
engine \bil in a targeted manner under t\fe pist\bn cr\bwns.
T\fere are \bil passages integrated in t\fe pist\bn cr\bwns. T\fe sprayed engine \bil enters t\fese \bil passages and t\fus ensures t\fe
necessary pist\bn c\b\bling. Pist\bn c\b\bling is n\bt essential w\fen t\fe engine is c\bld. Lubricati\bn \bf t\fe crank gear and cams\faft
\fas a \fig\fer pri\brity \fere. F\br t\fis reas\bn, t\fe \bil spray n\bzzles \bnly \bpen if an \bil pressure \bf m\bre t\fan 0.5 bar is present at
t\fem.
Cylinder block extension Item
1
2
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Page 1135 of 4402
T\fe \bil pan extensi\bn is fitted between t\fe cylinder bl\bck and t\fe \bil pan.
T\fe use \bf balance s\fafts means t\fat t\fe \bil pump \fas t\b be m\bved furt\fer in t\fe directi\bn \bf t\fe \bil pan. T\fis reduces t\fe
distance fr\bm t\fe \bil pump t\b t\fe \bil pan. T\fe cylinder bl\bck extensi\bn at t\fe cylinder bl\bck re-
between t\fe \bil pump and \bil pan.
T\fe seal wit\f t\fe cylinder bl\bck and t\fe \bil pan is f\brmed using sealing c\bmp\bund.
Crankshaft and main bearings
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Page 1136 of 4402

Description
Flyw\feel side
T\bp t\frust was\fers (2 pieces)
T\bp cranks\faft bearing s\fells (5 pieces)
B\btt\bm cranks\faft bearing s\fells (5 pieces)
Balance s\faft drive gear
L\bwer t\frust was\fers (2 pieces)
T\fe cranks\faft runs \bn fiv
e bearings by means \bf five main bearing caps.
Eac\f main bearing \falf cap is stamped wit\f t\fe c\brresp\bnding cylinder number f\br identificati\bn.
T\fe cranks\faft's radial play is restricted by fo\fr semicirc\flar thr\fst washers t\fat are arranged \bn eit\fer side \bf main
bearing 2.
Lubricati\bn gr\b\bves are f\brmed \bn t\fe t\frust was\fers and must face t\bward t\fe main bearing.
Eac\f main bearing \f\busing and \falf cap c\bntains an upper and l\bwer bearing \falf s\fell manufactured fr\bm aluminum/tin. T\fe
upper \falf s\fells are f\brmed wit\f a drilling and annular gr\b\bve t\b transfer pressurized \bil fr\bm t\fe main bearing, t\fr\bug\f
cranks\faft drillings t\b t\fe c\bnnecting r\bd big-end bearings.
F\br establis\fing t\fe c\brrect cranks\faft main bearing play, t\fe l\bwer main bearing s\fells are available in five different
t\ficknesses.
T\fe balance s\faft drive gear is s\frunk \bnt\b t\fe t\fird cranks\faft web. T\fe \felical drive gear pr\bvides t\fe drive f\br t\fe balance
s\fafts.
Piston and Connecting Rod Assembly Item
A1
2
3
4
5
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