Page 609 of 3229

ItemPart NumberDescription1-Pis t on2-Connect ing rod bearings3-Connect ing rod and cap ass emblyThe connect ing rods are 'L' profile forged with a t rapezium shaped (a s hape with 4 sides with 2 of it s s ides parallel) s mall end. Thebig end has a fract ure s plit bearing cap, which gives a s t able joint becaus e t he bearing cap and connecting rod are secured in t heact ual fract ure surface. Aluminium bearings are us ed for both t he lower and upper bearing half.
The pist ons are cast from a light -alloy met al cons ist ing of aluminium and s ilicon. The pist on s kirt is graphite coated at t he frontand rear to ens ure low frict ion bet ween t he pis ton and cylinder, part icularly during cold st art ing and during s hort periods ofext reme load. The pis ton is 'weight opt imis ed', which means, for example, that t he pis t on pin is comparat ively s hort and t hat t hepis ton is miss ing mat erial from t he s ides .
Each pis t on has 3 pis t on rings :
An upper compres sion ring of nit rat ed s teelA second ring of alloyed cast iron, which funct ions as bot h a compress ion ring and an oil s craper ringA 3-part oil ring made of nitrated s t eel
Piston Cooling Jets
Page 610 of 3229
ItemPart NumberDescription1-Pis t on cooling jet (6 off)Jet s locat ed in the cylinder block s pray oil on t o t he ins ide of t he pis ton t o provide pis t on and pis ton pin lubricat ion and cooling.The oil is dist ribut ed through t he cylinder block, via t he main oil gallery and channels bored in t he block.
Generator
ItemPart NumberDescription1-Rubber s leeve2-GeneratorThe generat or is locat ed at the rear of t he int ake side of t he cylinder block. The generator is driven by the crankshaft gearwheelvia t he auxiliary unit shaft gearwheel and t he auxiliary unit inner shaft gear wheel (s ee gear housing s ect ion for moreinformat ion).
Gear Housing Components
Page 611 of 3229
ItemPart NumberDescription1-Gear housing ass embly
ItemPart NumberDescription1-Generat or connect ion sleeve2-Front bearing3-Auxiliary unit inner s haft gear wheel4-Cams haft drive outer shaft gear wheel5-Rear bearing6-Cams haft chain gear wheel7-Pulley8-Cams haft drive s haft gear wheel9-Auxiliary unit s haft drive gear wheel10-Crankshaft gear wheel
Page 612 of 3229
11-O il pump gear wheel12-Int ermediat e s haft
ItemPart NumberDescription1-Pulley2-Auxiliary unit s haft3-Needle bearing4-Cam driving shaft5-Gear, camshaft chain6-Seal7-Double row bearing8-"Narrow" gear wheel (Scis sor gear) int ermediat e s haft9-"W ide" gear wheel, cam driving shaft10-Spring © spring)11-Gear wheel, auxiliary unit s haft12-Single row bearing wit h bearing hous ing13-Seal14-Sleeve connect ion, alt ernat or15-"Narrow" gear wheel (Scis sor gear) int ermediat e s haft , drives t he auxiliary unit s haft16-"W ide" gear wheel int ermediat e s haft , drives t he auxiliary unit shaft17-Small gear wheel int ermediate shaft , drives the cam driving s haft18-Double row conical bearing19-Int ermediat e s haft20-Spring © spring)The gear hous ing functions as an ext ernal cover for t he following sub-s ect ions :
Intermediat e s haftCams haft drive out er s haftAuxiliary unit inner s haft
Intermediate Shaft
Page 613 of 3229

The intermediat e s haft is us ed to locat e the cams haft drive s haft gear wheel in t he cylinder block. The shaft is journaled wit h adouble conical roller bearing. The auxiliary unit s haft drive gear wheel is in 2 pieces , wit h t he narrow half being s pring tensioned inthe opposit e direct ion t o t he wide half. This feat ure reduces nois e becaus e gear play is eliminat ed. Only t he wide half drives theauxiliary unit's gear wheel. The cams haft chain gear wheel is of t he conventional design.
The s haft is sealed against the exhaust side (i.e. the rear s ide of t he cylinder block) by a s ealing was her. To remove or inst all t hewasher, t he flywheel/flexplate must be removed.
Camshaft Drive O uter Shaft
The cams haft drive outer s haft is journaled at the front end of t he s haft with a double row bearing in t he gear hous ing. Needlebearings are us ed at t he rear end (pulley s ide) against t he auxiliary unit s haft . The camshaft drive out er s haft gear wheel is in 2pieces , a wide and a narrow half t o reduce nois e. The cams haft chain gear wheel is als o locat ed on the s haft and is us ed to drivethe cams hafts chain.
Auxiliary Unit Inner Shaft
The auxiliary unit inner s haft is journaled at t he front end of t he shaft (generator s ide) in t he gear housing with a s ingle rowbearing. Needle bearings are used at the rear end (pulley s ide) against the cams haft drive shaft . There is a pulley at t he rear endof the s haft that drives t he Air Condit ioning (AC) compress or and the power s t eering pump, via a polyvee belt . The shaft als odrives t he generat or at t he front end, via a sleeve connect or.
Thermostat Housing
ItemPart NumberDescription1-Thermost at hous ing2-Coolant t emperat ure s ens orThe t hermos tat hous ing is located t owards the front of t he int ake s ide of t he engine cylinder block. The hous ing contains a waxtype t hermost at and a coolant temperat ure sens or.
Coolant flows in at t he coolant pump and pas s es through a number of channels before it collect s and t hen flows out t o t hethermos t at housing. If t he t hermost at hous ing is closed, t he coolant pass es via t he by-pass channel directly to t he coolant pumpto then circulat e t hrough t he cylinder block againFor addit ional information, refer t o: Engine Cooling (303-03A Engine Cooling - I6 3.2L Pet rol, Des cription and Operat ion)..
Crankshaft Position Sensor
Page 614 of 3229
ItemPart NumberDescription1-CKP s ens or2-Sensor bracketThe Cranks haft Posit ion (CKP) sensor is locat ed at t he rear of the int ake s ide of t he cylinder block. The s ens or provides an input ofengine crankshaft speed and pos it ion. The sensor works on t he principle of t he Hall effect and s cans a trigger wheel (magnet icdis c) on t he flywheelFor addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation)..
Knock Sensors
Page 615 of 3229
ItemPart NumberDescription1-Front knock s ens or2-Rear knock s ens orThe knock s ens ors are locat ed at t he front and rear int ake side of t he cylinder block. They are piezo-elect ric s ens ors t hat provideinput s t o detect and locate det onation during combust ionFor addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation)..
Coolant Pump
Page 616 of 3229

ItemPart NumberDescription1-Seal2-Coolant pumpThe coolant pump is ins t alled on t he RH side of t he cylinder block rear face and is s ecured and s ealed via 6 bolt s and an 'O' ring.The coolant pump and power s t eering pump are bot h driven by a single pulley via a poly-vee belt . A keyed s haft at the front of t hepulley drives t he power s teering pump, while a driver mechanism at t ached to t he rear of t he pulley drives the coolant pump.
Coolant Inlet Pipe
ItemPart NumberDescription1-O ring2-Coolant inlet pipe3-Gas ket (2 off)4-Drain nippleThe coolant inlet pipe is locat ed on t he exhaus t s ide of the engine. The coolant is rout ed from t he coolant pump int o 2connect ions on the engine block via t he coolant inlet pipe and leaves t he engine block at t he rear end, via t he t hermos tat hous ing.
CYLINDER HEAD COMPONENTS
The main cylinder head component s are:
Cylinder headCylinder head gas ketO il s eparat orCams haft hous ingCams haftsIntake and exhaust valve ass embliesVariable Cams haft Timing (VCT) s olenoid and Cams haft Posit ion (CMP) sens orsSpark plugsCoilsFuel rail and injectorsVacuum pumpIntake manifoldExhaus t manifold
Cylinder Head