Musso

SECTION INDEX
SERVICE
MANUAL FRONT MATTER 0A
MUSSO GENERAL INFORMATION 0B
ENGINE 1
SUSPENSION 2
FOREWORD DRIVE LINE/AXLE 3
This manual includes procedure for mainte-

nance, adjustment, service operation and re- BRAKES 4
moval and installation of components.
All information, illustrations and specifications

contained in this manual are based on the latest TRANSMISSION 5
product information available at the time of
manual approval.
The right is reserved to make changes at any STEERING 6

time without notice.
HVAC
(HEATING, VENTILATION, 7
AND AIR CONDITIONING)
DAEWOO MOTOR CO., LTD.
RESTRAINTS 8
INCHON, KOREA
BODY AND ACCESSORIES 9

PERSONAL INJURY CAUTION
Appropriate service methods and proper repair procedure are essential
for the safe, reliable operation of all motor vehicles, as well as for the
personal safety of the person doing the repair. There are many
variations in procedures, techniques, tools and parts for servicing
vehicles, as well as in the skills of the people doing the work. This
manual cannot possibly anticipate all such variations and provide advice
or precautions for each. Anyone who deviates from the instructions
provided in this manual must ensure their own safety and preserve
the safety and integrity of the vehicle. The following list contains general
precautions that should always be followed while working on a vehicle.
• Safety stands are required whenever a procedure calls for
underbody work.
• Do not smoke when you work on a vehicle.
• To prevent serious burns, do not touch any hot metal parts.
• Set the parking brake when you work on the vehicle.
• Turn the ignition switch OFF unless a procedure states
otherwise.
• The engine may operate only in a well-ventilated area.
• Avoid moving parts when the engine is running.
• Safety glasses must be worn for eye protection.
MUSSO
Service Manual
FOREWORD
This manual includes procedures for maintenance, adjustment, service operations, and re-
moval and installation of components for the MUSSO vehicle.
When reference is made in this manual to a brand name, number, or specific tool, an equiva-
lent product may be used in place of the recommended item.
All information, illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication approval. The right is reserved to make
changes at any time without notice.
Daewoo Motor Company, Limited

Overseas Technical Service Department
391-9 Chong Chon-2 Dong, Pu Pyung-Gu,
Inchon, Korea
Tel : 82-32-509-4161 ~ 4164
Fax : 82-32-509-4160
E-mail : m8610452@dwmc.co.kr
m9610883@dwmc.co.kr
Daewoo Motor Company, Limited

All rights Reserved
No part of this publication may be reproduced, stored in any retrieval system or transmitted, in
any form or by any means, including but not limited to electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of Daewoo Motor Company, Lim-
ited
TABLE OF CONTENTS
Section 0A Front Matter Section 5 Transmission
Section 5A Automatic Transmission
Section 0B General Information
Section 5B Manual Transmission
Section 1 Engine Section 5C Clutch
Section 1A1 M162 General Engine Information Section 5D1 Transfer Case (Part Time 4480)
Section 1B1 M162 Engine Mechanical Section 5D2 Transfer Case (TOD)
Section 1D1 M162 Engine Cooling
Section 1E1 M162 Engine Electrical Section 6 Steering
Section 1F1 M162 Engine Controls Section 6A Power Steering System
Section 1G1 M162 Engine Intake & Exhaust Section 6E Steering Wheel and Column
Section 1A2 M161 General Engine Information Section 7 HVAC (Heating, Ventilation & Air
Section 1B2 M161 Engine Mechanical Conditioning)
Section 1D2 M161 Engine Cooling Section 7B/C Manual Control/Semiauto Tempera-
Section 1E2 M161 Engine Electrical ture Control Heationg, Ventilation,
Section 1F2 M161 Engine Controls and Air Conditioning System
Section 1G2 M161 Engine Intake & Exhaust Section 7D Full Automatic Temperature Control
Heationg, Ventilation, and Air Condi-
Section 1A3 OM600 General Engine Information
tioning System
Section 1B3 OM600 Engine Mechanical
Section 1D3 OM600 Engine Cooling Section 8 Restraints
Section 1E3 OM600 Engine Electrical Section 8A Seat Belts
Section 1F3 OM600 Engine Controls Section 8B Supplemental Restraint System
Section 1G3 OM600 Engine Intake & Exhaust (SRS)
Section 2 Suspension Section 9 Body and Accessories

Section 2A Suspension Diagnosis Section 9A Body Wiring System
Section 2B Wheel Alignment Section 9B Lighting Systems
Section 2C Front Suspension Section 9D Wipers/Washer Systems
Section 2D Rear Suspension Section 9E Instrumentation/Driver Information
Section 2E Tires and Wheels Section 9F Audio
Section 9H Seats
Section 3 Drive Line / Axle
Section 9L Glass and Mirrors
Section 3A Front Drive Axle
Section 9N Front and Under Body
Section 3C Propeller Shaft
Section 9O Bumpers and Fenders
Section 3D Rear Drive Axle
Section 9P Doors
Section 4 Brakes Section 9Q Roof
Section 4A Hydraulic Brakes Section 9R Body Front End
Section 4B Master Cylinder Section 9T Remote Keless Entry and Anti-Theft
Section 4C Power Booster System
Section 4D Front Disc Brakes Section 9U Control Units and System
Section 4E Rear Disc Brakes Section 9W Immobilizer System
Section 4F Antilock Brake System
Section 4G Parking Brakes
MUSSO
SERVICE MANUAL
ISSUED BY
OVERSEAS TECH. SERVICE
DAEWOO MOTOR CO., LTD.
391-9 CHONG CHON-2DONG, PU PYUNG-GU,

INCHON, KOREA
TELEPHONE : 82-32-509-4161~4164
FACSIMILE : 82-32-509-4160
ENGINE
CONTENTS
SECTION 1A1 M162 GENERAL ENGINE INFORMATION

SECTION 1B1 M162 ENGINE MECHANICAL
SECTION 1D1 M162 ENGINE COOLING
SECTION 1E1 M162 ENGINE ELECTRICAL
SECTION 1F1 M162 ENGINE CONTROLS
SECTION 1G1 M162 ENGINE INTAKE & EXHAUST
SECTION 1A2 M161 GENERAL ENGINE INFORMATION
SECTION 1B2 M161 ENGINE MECHANICAL
SECTION 1D2 M161 ENGINE COOLING
SECTION 1E2 M161 ENGINE ELECTRICAL
SECTION 1F2 M161 ENGINE CONTROLS
SECTION 1G2 M161 ENGINE INTAKE & EXHAUST
SECTION 1A3 OM600 GENERAL ENGINE INFORMATION
SECTION 1B3 OM600 ENGINE MECHANICAL
SECTION 1D3 OM600 ENGINE COOLING
SECTION 1E3 OM600 ENGINE ELECTRICAL
SECTION 1F3 OM600 ENGINE CONTROLS
SECTION 1G3 OM600 ENGINE INTAKE & EXHAUST
SUSPENSION
CONTENTS
SECTION 2A SUSPENSION DIAGNOSIS

SECTION 2B WHEEL ALIGNMENT
SECTION 2C FRONT SUSPENSION
SECTION 2D REAR SUSPENSION
SECTION 2E TIRES AND WHEELS
DRIVE LINE / AXLE
CONTENTS
SECTION 3A FRONT DRIVE AXLE

SECTION 3C PROPELLER SHAFT
SECTION 3D REAR DRIVE AXLE
BRAKE
CONTENTS
SECTION 4A HYDRAULIC BRAKES

SECTION 4B MASTER CYLINDER
SECTION 4C POWER BOOSTER
SECTION 4D FRONT DISC BRAKES
SECTION 4E REAR DISC BRAKES
SECTION 4F ANTILOCK BRAKE SYSTEM
SECTION 4G PARKING BRAKE
TRANSMISSION
CONTENTS
SECTION 5A AUTOMATIC TRANSMISSION

SECTION 5B MANUAL TRANSMISSION
SECTION 5C CLUTCH
SECTION 5D1 TRANSFER CASE (PART TIME 4408)
SECTION 5D2 TRANSFER CASE (TOD)
STEERING
CONTENTS
SECTION 6A POWER STEERING SYSTEM

SECTION 6E STEERING WHEEL AND COLUMN
HVAC (HEATING, VENTILATION &
AIR CONDITIONING)
CONTENTS
SECTION 7B/C MANUAL CONTROL/SEMIAUTO

TEMPERATURE CONTROL
HEATING, VENTILATION, AND
AIR CONDITIONING SYSTEM
SECTION 7D FULL AUTOMATIC
TEMPERATURE CONTROL
HEATING, VENTILATION, AND
AIR CONDITIONING SYSTEM
RESTRAINTS
CONTENTS
SECTION 8A SEAT BELTS

SECTION 8B SUPPLEMENTAL RESTRAINT
SYSTEM (SRS)
BODY AND ACCESSORIES
CONTENTS
SECTION 9A BODY WIRING SYSTEM

SECTION 9B LIGHTING SYSTEM
SECTION 9C HORNS
SECTION 9D WIPERS/WASHER SYSTEM
SECTION 9E INSTRUMENTATION/DRIVER INFORMATION
SECTION 9F AUDIO SYSTEM
SECTION 9H SEATS
SECTION 9L GLASS AND MIRRORS
SECTION 9N FRAME AND UNDERBODY
SECTION 9O BUMPERS AND FASCIAS
SECTION 9P DOORS
SECTION 9Q ROOF
SECTION 9R BODY FRONT END
SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT
SYSTEM
SECTION 9U CONTROL UNITS AND SYSTEM
SECTION 9W IMMOBILIZER SYSTEM
SECTION 0B
GENERAL INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 While Operating the Vehicle . . . . . . . . . . . . . 0B-12
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . 0B-12
Vehicle Dimensions and Weights . . . . . . . . . . 0B-5 At Least Twice A Month . . . . . . . . . . . . . . . . 0B-12
Standard Bolt Specifications . . . . . . . . . . . . . . 0B-6 At Least Monthly . . . . . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Repair . . . . . . . . . . . . . . . 0B-7 At Least Twice a Year . . . . . . . . . . . . . . . . . . 0B-12
Maintenance and Lubrication . . . . . . . . . . . . . . 0B-7 Each Time the Oil is Changed . . . . . . . . . . . 0B-13
Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . 0B-7 At Least Annually . . . . . . . . . . . . . . . . . . . . . 0B-13
Explanation of Scheduled Maintenance Recommended Fluids and Lubricants . . . . . 0B-14
Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-7 General Description and System
Scheduled Maintenance Charts Operation . . . . . . . . . . . . . . . . . . . . . . . . 0B-15
(Gasoline Engine) . . . . . . . . . . . . . . . . . . . . . 0B-8 General Repair Instructions . . . . . . . . . . . . . 0B-15
Scheduled Maintenance Charts Vehicle Identification Number System . . . . . . 0B-16
(Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . 0B-10
Vehicle Lifting Procedures . . . . . . . . . . . . . . 0B-19
Owner Inspections and Services . . . . . . . 0B-12
SPECIFICATIONS
TECHNICAL DATA
Transaxle Performance
Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 143 145 156 168 176 190
Minimum Turning Radius (m) 5.7 5.7 5.7 5.7 5.7 5.7
Performance-Autumatic Transaxle (MB)

Application 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 171 190
Minimum Turning Radius (m) 5.7 5.7
Performance-Autumatic Transaxle (BTRA)

Application 661LA 662NA 662LA 2.3L DOCH 3.2L DOCH
Maximum Speed (Km/h) 143 138 156 171 188
Minimum Turning Radius (m) 5.7 5.7 5.7 5.7 5.7
0B-2 GENERAL INFORMATION
Engine
Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH
Engine Type 4Cylinder 5Cylinder 5Cylinder 4Cylinder 4Cylinder 6Cylinder
DIESEL DIESEL DIESEL GASOLINE GASOLINE GASOLINE
Bore (mm) 89 89 89 89.9 90.9 89.9
Stroke (mm) 92.4 92.4 92.4 78.7 88.4 84
Total Displacement (cc) 2299 2874 2874 1998 2295 3199
Compression Ratio 22:1 22:1 22:1 9.6:1 10.4:1 10:1
Maximum Power (ps/rpm) 101/4000 95/4000 120/4000 135/5500 149/5500 222/5500
Maximum Torque (kg.m/rpm) 21.5/2400 19.6/2400 25.5/2400 19.3/4000 22.4/4000 31.6/3750
Ignition System
Application 2.0L DOHC 2.3L DOHC 2.0L DOHC
Ignition Type Distributorless Ignition
Ignition Timing (BOTH) 6°± 2° 6°± 2° 8°± 2°
Ignition Sequence 1-3-4-2 1-3-4-2 1-5-3-6-2-4
Spark Plug Gap (mm) 0.8 ± 0.1 0.8 ± 0.1 0.8 ± 0.1
Spark Plug Maker Bosch, Chapion, Beru
Spark Plug Type F8DC4(BOSCH)
C11YCC(CHAMPION)
14F8DU4(BERU)
Clutch - Manual Type

Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Type Single Dry Diaphram
Outside Diameter (mm) 225 225 240 225 225 240
Inside Diameter (mm) 150 150 150 150 150 155
Thickness 9.2 9.2 9.2 9.2 9.2 9.3
Fluid Common use :Brake Fluid
Manual Transmission
Maker TREMEC TREMEC TREMEC TREMEC TREMEC TREMEC
Type or Model T5 T5 T5 T5 T5 T5
Gear Ratio : 1st 3.969 3.969 3.969 3.969 3.969 3.969
2nd 2.341 2.341 2.341 2.341 2.341 2.341
3rd 1.457 1.457 1.457 1.457 1.457 1.457
4th 1.000 1.000 1.000 1.000 1.000 1.000
5th 0.851 0.851 0.851 0.851 0.851 0.851
Reverse 3.705 3.705 3.705 3.705 3.705 3.705
Final Drive Ratio 4.55 4.55 4.27 4.55 4.55 3.73
Oil Capacity (L) 3.4 3.4 3.4 3.4 3.4 3.4
GENERAL INFORMATION 0B-3
Auto Transmission (MB)
Application 662LA 2.3L DOHC 3.2L DOHC
Maker MB MB MB
Type or Model W4A040 W4A040 W4A040
Gear Ratio : 1st 3.871 3.871 3.871
2nd 2.247 2.247 2.247
3rd 1.436 1.436 1.436
4th 1.000 1.000 1.000
Reverse 5.586 5.586 5.586
Final Drive Ratio 5.38 4.27 3.73
Oil Capacity (L) 9 - 9.5 9 - 9.5 9 - 9.5
Auto Transmission (BTRA)

Application 661LA 662LA 2.3L DOHC 3.2L DOHC
Maker BTRA BTRA BTRA BTRA
Type or Model M74 4WD M74 4WD M74 4WD M74 4WD
Gear Ratio : 1st 2.741 2.741 2.741 2.741
2nd 1.508 1.508 1.508 1.508
3rd 1.000 1.000 1.000 1.000
4th 0.708 0.708 0.708 0.708
Reverse 2.429 2.429 2.429 2.429
Final Drive Ratio 5.38 4.89 5.86 4.89
Oil Capacity (L) 9 9 9 9
Brake
Application Specifications
Booster Size non-ABS 8inch + 9inch
ABS 5.0 7inch + 8inch
ABS 5.3 8inch + 9inch
Master Cylinder Diameter (mm) f 25.4
Booster Ratio 5.6 : 1
Front Brake : Disc Type Ventilated
Rear Brake : Disc Type Solid
Tire and Wheel

Standard Tire Size P235/75 R15, 255/70 R15
Standard Wheel Size 7JJ ´ 15
Inflation Pressure At Full Lode
P235 / 75 : Front 30 Psi
Rear 30 Psi
P255 / 75 : Front 30 Psi
Rear 30 Psi
Steering System
Gear Type RACK & PINION
Wheel Alignment:
Front Toe-in 0 - 4 mm
Front Caster 2°30’± 30’
Front Camber 0° ± 30’
Oil Capacity 1L
Suspension
Front Type Double Wishbone
Rear Type 5 - Link
Fuel System
Fuel Pump Type Electric Motor Pump
Fuel Filter Type Cartridge
Fuel Capacity 70 L
Lubricating System
Lubricating Type 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Oil Pump Type External Gear pump
Oil Filter Type Combination(Full & Part) Full Flow
Oil Capacity (L) (Including Oil Filter) 8.0 9.0 9.5 7.2 7.5 8.2
Cooling System
Cooling Type 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC 3.2L DOHC
Coolant Capacity (L) 9.5-10 10.5 10.5-11 10.5 10.5 11.3
Radiator Type Forced Circulation
Water Pump Type Centrifugal
Electric System
Battery (MF) 12V - 90AH 12V - 75AH
Generator 75A 75A 75A 115A 115A 115A
Starter 2.2kw 2.2kw 2.2kw 1.2kw 1.2kw 1.7kw
VEHICLE DIMENSIONS AND WEIGHTS

Vehicle Dimensions
Application Application
Overall Length (mm) 4656
Overall Width (mm) 1864
Overall Height (mm) 1735
Wheel Base (mm) 2630
Tread : Front (mm) 1510
Rear (mm) 1520
Vehicle Weights
Manual : Curb Weight (kg) 1860 1968 1890 1937 1850 1930
Gross Vehicle Weight (kg) 2520 2520 2520 2520 2520 2520
Automatic : Curb Weight (kg) 1916 1989 2005 - 1942 2025
Gross Vehicle Weight (kg) 2520 2520 2520 - 2520 2520
Passenger Capacity 5 5 5 5 5 5
STANDARD BOLTS SPECIFICATIONS

Torque (N·m / Ib-in)
Bolt* Standard Limit
4T 7T 9T 4T 7T 9T
M3 ´ 0.5 0.5 N·
·m 0.9 N··m 1.3 N·
·m 0.7 N··m 1.2 N·
·m 17 N··m
(4.5 lb-in) (8 lb-in) (12 lb-in) (6.3 lb-in) (11 lb-in) (15 lb-in)
M4 ´ 0.7 1.2 N·
·m 2.0 N··m 3.0 N·
·m 1.6 N··m 2.6 N·
·m 4.0 N·
·m
(11 lb-in) (18 lb-in) (27 lb-in) (14 lb-in) (23 lb-in) (36 lb-in)
M5 ´ 0.8 2.4 N·
·m 4.0 N··m 5.6 N·
·m 3.1 N··m 5.2 N·
·m 7.6 N·
·m
M6 ´ 1.0 4.0 N·
·m 6.7 N··m 9.7 N·
·m 5.4 N··m 9.0 N·
·m 12.7 N· ·m
M8 ´ 1.25 8.6 N·
·m 15.7 N· ·m 22.5 N··m 12.7 N· ·m 20.6 N··m 30.4 N· ·m
(77 lb-in) (12 lb-in) (17 lb-in) (9 lb-in) (15.2 lb-in) (22 lb-in)
M10 ´ 1.25 18.6 N··m 32.3 N· ·m 46.0 N··m 25.5 N· ·m 42.1 N··m 60.8 N· ·m
M10 ´ 1.5 18.6 N··m 30.4 N· ·m 44.1 N··m 24.5 N· ·m 41.2 N··m 58.8 N· ·m
M12 ´ 1.25 34.3 N··m 56.8 N· ·m 82.3 N··m 45.0 N· ·m 75.5 N··m 107.8 N· ·m
(25lb-in) (42 lb-in) (61 lb-in) (33 lb-in) (56 lb-in) (80 lb-in)
M12 ´ 1.75 32.3 N··m 53.9 N· ·m 77.4 N··m 43.1 N· ·m 71.5 N··m 98.0 N· ·m
M14 ´ 1.5 54.0 N··m 89.2 N· ·m 127.4 N· ·m 71.6 N· ·m 117.6 N· ·m 166.6 N· ·m
M16 ´ 1.5 81.3 N··m 107.8 N· ·m 196.0 N· ·m 107.8 N· ·m 186.2 N· ·m 264.6 N· ·m
M18 ´ 1.5 117.6 N· ·m 196.0 N· ·m 284.2 N· ·m 156.8 N· ·m 264.6 N· ·m 372.4 N· ·m
M20 ´ 1.5 166.6N· ·m 274.4 N· ·m 392.0 N· ·m 215.6 N· ·m 362.6 N· ·m 519.4 N· ·m
M22 ´ 0.5 225.4N· ·m 372.4 N· ·m 529.2 N· ·m 294.0 N· ·m 490.0 N· ·m 705.6 N· ·m
M24 ´ 1.5 284.2 N· ·m 480.2 N· ·m 686.0 N· ·m 382.2 N· ·m 637.0 N· ·m 921.2 N· ·m
M24 ´ 2.0 274.4 N· ·m 460.6 N· ·m 666.4 N· ·m 372.4 N· ·m 617.4 N· ·m 891.8 N· ·m
*Diameter ´ pitch in millimeters

MAINTENANCE AND REPAIR

MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE Fuel Filter Replacement
The maintenance instructions contained in the Replace the engine fuel filter every.
maintenance schedule are based on the assumption l Gasoline Engine : 60,000km (36,000 miles)
that the vehicle will be used for the following reasons: l Diesel Engine : 45,000km (24,000 miles)
l To carry passengers and cargo within the limitation
Spark Plug Replacement
of the tire inflation prassure. Refer to “Tire and Wheel”
in section 2E. Replace spark plugs with same type.
l To be driven on reasonable road surfaces and within l Type : BOSCH : F8DC4
legal operating limits. BERU : 14F-8DU4
Champion : C11YCC
EXPLANATION OF SCHEDULED l Gap : 0.8 ± 0.1 mm
MAINTENANCE SERVICES Spark Plug Wire Replacement

Clean wires and inspect them for burns, cracks or other
The services listed in the maintenance schedule are
damage. Check the wire boot fit at the Distributor and at
further explained below. When the following maintenance
the spark plugs. Replace the wires as needed.
services are performed, make sure all the parts are
replaced and all the necessary repairs are done before Brake System Service
driving the vehicle. Always use the proper fluid and Check the disc brake pads or the drum brake linings.
lubricants. Check the pad and the lining thickness carefully.
Engine Oil and Oil Filter Change Tire and Wheel Inspection and Rotation
Always use above the API SH grade or recommended Check the tires for abnormal wear or damage. To
engine oil. equalize wear and obtain maximum tire life, rotate the
Engine Oil Viscosity tires. If irregular or premature wear exists, check the
wheel alignment and check for damaged wheels. While
Engine oil viscosity (thickness) has an effect on fuel
the tires and wheels are removed, inspect the brakes.
economy and cold weather operation. Lower viscosity
engine oils can provide better fuel economy and cold
weather performance; however, higher temperature Tire Rotation (Left - Hand Drive Type)
weather conditions require higher viscosity engine oils
for satisfactory lubrication. Using oils of any viscosity
other than those viscosities recommended could result
in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer
to “Recommended Fluids And Lubricants” in this section.
Air Cleaner Element Replacement
Clean the air cleaner element every.
l Gasoline Engine : 15,000km (10,000 miles)
l Diesel Engine : 10,000km (6,000 miles)
Replace the air cleaner element every .
l Gasoline Engine : 60,000km (36,000 miles)
l Diesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty
conditions.
SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)
Engine
MAINTENANCE INTERVAL Kilometers or time in months, whichever comes first
x1,000 km 1 15 30 45 60 75 90 105 120
MAINTENANCE
ITEM Months - 12 24 36 48 60 72 84 96
Drive belt I I I I I I I I I
Engine oil & filter (1) (3) I R R R R R R R R
Cooling system hose & connections I I I I I I I I I
Engine coolant (3) I I I I R I I I R
Fuel filter (2) - - - - R - - - R
Fuel line & connections I I I I I I I I I
Air cleaner (2) I I I R I I R
Ignition timing I I I I I I I I
Spark plugs - I R I R I R I R
Charcoal canister & vapor lines - - - I - - I - -
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R - Replace or change.
(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition. Change
engine oil and the filter every 7,500 km or 6 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving condition.
(3) Refer to “Recommended fluids and lubricants”.
Chassis and Body
x1,000 km 1 15 30 45 60 75 90 105 120
MAINTENANCE
ITEM Months - 12 24 36 48 60 72 84 96
Exhaust pipes & mountings - I I I I I I I I
Brake/Clutch fluid (3)(4) - I R I R I R I R
Parking brake/Brake pads F & R (5) - I I I I I I I I
Brake line & connections (including booster) I I I I I I I I I
Manual transmission oil (3) I I I R I I R I I
Clutch & brake pedal free play - I I I I I I I I
Front & Rear Differential Fluid (3) I I I R I I R I I
Transfer case fluid I I I R I I R I I
Automatic transmission fluid (MB W4A040) (6) I I I R I I R I
Automatic transmission fluid (BTRA M74) I I I I I I I I I
Chassis & underbody bolts & nuts tight/secure I I I I I I I I I
Tire condition & inflation pressure I I I I I I I I I
Wheel alignment (7) Inspect & ADJUST when abnormal condition is noted
Steering wheel & linkage I I I I I I I I
Power steering fluid & lines* (3) I I I I I I I I
Drive shaft boots I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I I
Lubricate locks, hinges & bonnet latch I I I I I I I I
Chart Symbols :
(4) Change the brake / clutch fluid every 15,000 km if the vehicle is mainly driven under severe conditions:
- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low -
speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transaxle fluid and filter every 75,000 km if the vehicle is mainly driven under severe conditions.
- In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
- In hilly or mountainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.
SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)
Engine
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
MAINTENANCE
ITEM Months - 6 12 18 24 30 36 42 48 54 60
Drive belt I I I I I I I I I I I
Engine oil & fillter (1) (3) R R R R R R R R R R R
Cooling system hose & connections I I I I I I I I I
Engine coolant (3) I R I
Fuel filter (2) R R
Fuel line & connections I I I I I I I I I I I
Glow plug I I I R I
Pre - fuel filter I I I I I I I I I I
Air cleaner (2) I I R I I R I I R I
Ignition timing (see NOTE 1) I I I I I I I I I I
NOTE 1 : Injection Timing :
Adjust as required :
- When excessive smoke is visible (black or white)
- Poor performance/economy
Chart Symbols:
(1) If vehicle is operated under severe condition : short distance driving, extensive idling or driving in dusty condition, change
engine oil every 5,000km or 3 months, whichever comes first.
(2) More frequent maintenance is required if under dusty driving conditing.
Chassis and Body
x1,000 km 1 10 20 30 40 50 60 70 80 90 100
MAINTENANCE
ITEM Months - 6 12 18 24 30 36 42 48 54 60
Exhaust pipes & mountings I I I I I I I I I I
Brake/clutch fluid (3) (4) I I I R I I R I I R I
Parking brake/Brake pads (F & R) (5) I I I I I I I I I I
Brake line & connections (including booster) I I I I I I I I I I
Manual transmission fluid (3) I I I I R I I I I R
Clutch & brake pedal free play I I I I I I I I I I
F & R Differential fluid (3) I I I I I R I I I I R
Transfer case fluid (3) I I I I R I I I I R
Automatic transmission fluid (BTRA M74) (6) I I I I I I I I I I
Chassis & underbody bolts & nuts tight/secure I I I I I I I I I I I
Tire condition & inflation pressure I I I I I I I I I I I
Wheel alignment (7) Inspect & ADJUST when abnormal condition is noted
Steering wheel & linkage I I I I I I I I I I
Power steering fluid & lines* (3) I I I I I I I I I I
Drive shaft boots I I I I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I I I I
Lubricate locks, hinges & bonnet latch I I I I I I I I I I I
Chart Symbols :
(4) Change the brake / clutch fluid more regularly if the vehicle is mainly driven under severe conditions :
- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low -
speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transmission fluid every 70,000 km if the vehicle is mainly driven under severe conditions.
- In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
- In hilly or mountainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.
5. Add oil, if needed, to keep the oil level above the
OWNER INSPECTIONS lower mark. Avoid overfilling the engine, since this
AND SERVICES may cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.
WHILE OPERATING THE VEHICLE If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the
Horn Operation pan fast enough to give a true oil level reading.
Blow the horn occasionally to make sure it works. Check Engine Coolant Level and Condition
all the button locations.
Check the coolant level in the coolant reservoir tank
Brake System Operation and add coolant if necessary. Inspect the coolant.
Be alert for abnormal sounds, increased brake pedal Replace dirty or rusty coolant.
travel or repeated puling to one side when braking. Also, Windshield Washer Fluid Level
if the brake warning light goes on, or flashes, something
may be wrong with part of the brake system. Check the washer fluid level in the reservoir. Add fluid if
necessary.
Exhaust System Operation
Be alert to any changes in the sound of the system or AT LEAST TWICE A MONTH
the smell of the fumes. These are signs that the system Tire And Wheel Inspection and Pressure
may be leaking or overheating. Have the system
inspected and repaired immediately.
Check
Check the tire for abnormal wear or damage. Also check
Tires, Wheels and Alignment Operation for damaged wheels. Check the tire pressure when the
Be alert to any vibration of the steering wheel or the tires are cold ( check the spare also, unless it is a
seats at normal highway speeds. This may mean a wheel stowaway). Maintain the recommended pressures. Refer
needs to be balanced. Also, a pull right or left on a to “Tire and Wheel” is in section 0B.
straight, level road may show the need for a tire pressure
adjustment or a wheel alignment. AT LEAST MONTHLY
Steering System Operation Light Operation
Be alert to changes in the steering action. An inspection Check the operation of the license plate light, the
is needed when the steering wheel is hard to turn or headlights (including the high beams), the parking lights,
has too much free play, or is unusual sounds are noticed the fog lights, the taillight, the brake lights, the turn
when turning or parking. signals, the backup lights and the hazard warning flasher.
Headlight Aim Fluid Leak Check
Take note of the light pattern occasionally. Adjust the Periodically inspect the surface beneath the vehicle for
headlights if the beams seem improperly aimed. water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air
AT EACH FUEL FILL conditioning system after use is normal. If you notice
A fluid loss in any (except windshield washer) system fuel leaks or fumes, find the cause and correct it at once.
may indicate a problem. Have the system inspected and
repaired immediately. AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Engine Oil Level
Check the power steering fluid level. Keep the power
Check the oil level and add oil if necessary. The best
steering fluid at the proper level. Refer to Section 6A,
time to check the engine oil level is when the oil is warm.
Power Steering System.
1. After stopping the engine, wait a few minutes for the
oil to drain back to the oil pan. Brake Master Cylinder Reservoir Level
2. Pull out the oil level indicator (dip stick). Check the fluid and keep it at the proper level. A low
3. Wipe it clean, and push the oil level indicator back fluid level can indicate worn disc brake pads which may
down all the way. need to be serviced. Check the breather hole in the
reservoir cover to be free from dirt and check for an
4. Pull out the oil level indicator and look at the oil level open passage.
on it.
Weather-Strip Lubrication AT LEAST ANNUALLY
Apply a thin film silicone grease using a clean cloth.
Lap and Shoulder Belts Condition and
EACH TIME THE OIL IS CHANGED Operation
Inspect the belt system including: the webbing, the
Brake System Inspection buckles, the latch plates, the retractor, the guide loops
This inspection should be done when the wheels are and the anchors.
removed for rotation. Inspect the lines and the hoses
for proper hookup, binding, leaks, cracks, chafing, etc. Movable Head Restraint Operation
Inspect the disc brake pads for wear. Inspect the rotors On vehicles with movable head restraints, the restraints
for surface condition. Inspect other brake parts, the must stay in the desired position.
parking brake, etc., at the same time. Inspect the brakes
Spare Tire and Jack Storage
more often if habit or conditions result in frequent braking.
Be alert to rattles in the rear of the vehicle. The spare
Steering, Suspension and Front Drive Axle tire, all the jacking equipment, and the tools must be
Boot And Seal Inspection securely stowed at all times. Oil the jack ratchet or the
Inspect the front and rear suspension and the steering screw mechanism after each use.
system for damaged, loose or missing parts, signs of Key Lock Service
wear or lack of lubrication. Inspect the power steering
Lubricate the key lock cylinder.
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle Body Lubrication Service
boot and seals for damage, tears or leakage. Replace Lubricate all the body door hinges including the hood,
the seals if necessary. the fuel door, the rear compartment hinges and the
Exhaust System Inspection latches, the glove box and the console doors, and any
folding seat hardware.
Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the exhaust Underbody Flushing
system. Look for broken, damaged, missing, or out-of- Flushing the underbody will remove any corrosive
position parts as well as open seams, holes, loose materials used for ice and snow removal and dust control.
connections, or other conditions which could cause heat At least every spring clean the underbody. First, loosen
buildup in the floor pan or could let exhaust fumes seep the sediment packed in closed areas of the vehicle. Then
into the trunk or passenger compartment. flush the underbody with plain water.
Throttle Linkage Inspection Engine Cooling System
Inspect the throttle linkage for interference or binding, Inspect the coolant and freeze protection fluid. If the fluid
damaged, or missing parts. Lubricate all linkage joints is dirty or rusty, drain, flush and refill the engine cooling
and throttle cable joints, the intermediate throttle shaft system with new coolant. Keep the coolant at the proper
bearing, the return spring at throttle valve assembly, and mixture in order to ensure proper freeze protection,
the accelerator pedal sliding face with suitable grease. corrosion protection and engine operating temperature.
Check the throttle cable for free movements. Inspect the hoses. Replace the cracked, swollen, or
Engine Drive Belts deteriorated hoses. Tighten the clamps. Clean the
outside of the radiator and the air conditioning
Inspect all belts for cracks, fraying, wear and proper
condenser. Wash the filler cap and the neck. Pressure
tension. Adjust or replace the belts as needed.
test the cooling system and the cap in order to help
Hood Latch Operation ensure proper operation.
When opening the hood, note the operation of the
secondary latch. It should keep the hood from opening
all the way when the primary latch is released. The hood
must close firmly.
RECOMMENDED FLUIDS AND LUBRICANTS

Usage Capacity Fluid/Lubricant
Engine Oil 3.2L DOHC 8.2 L Quality class - API ; SH grade or above
(Change with filter) ACEA ; A2 or A3
2.3L DOHC 7.5 L MB sheet ; 229.1
Viscosity - MB sheet ; 224.1
662LA 9.5 L Quality class - API ; CG grade or above
ACEA ; B2 or B3
661LA 8.0 L MB sheet ; 228.1, 228.3,
228.5, 229.1
Viscosity - MB sheet ; 224.1
Engine Coolant 3.2L DOHC 11.3 L ALUTEC P-78
2.3L DOHC 10.5 L
662LA 10.5 - 11.0 L
661LA 9.5 - 10.0 L
Brake / Clutch Fluid Approx. 0.5L level must DOT-3 & SAE J 1703
be maintained between
MAX & MIN level
Power Steering System 1.0 L ATF DEXRON-II
Parking Brake Cable As required Grease
Hood Latch Assembly As required Grease
Hood and Door Hinges As required Spray type grease
Fuel Door Hinge
Rear Compartment Lid Hinges
Weatherstrips As required Silicone grease
l Use genuine DAEWOO parts.
GENERAL DESCRIPTION l Discard used cotter pins, gaskets, O-rings, oil seals,
AND SYSTEM OPERATION lock washers and self-locking nuts. Prepare new ones
for installation. Normal function of these parts cannot
be maintained if these parts are reused.
GENERAL REPAIR INSTRUCTIONS
l Keep the disassembled parts neatly in groups to
l If a floor jack is used, the following precautions are facilitate proper and smooth reassembly.
recommended.
l Keep attaching bolts and nuts separated, as they
l Park the vehicle on level ground, “block” the front or vary in hardness and design depending on the
rear wheels, set the jack against the frame, raise the position of the installation.
vehicle and support it with chassis stands and then
perform the service operation. l Clean the parts before inspection or reassembly.
l Before performing the service operation, disconnect l Also clean the oil parts, etc. Use compressed air to
the negative battery cable in order to reduce the make certain they are free of restrictions.
chance of cable damaged and burning due to short- l Lubricate rotating and sliding faces of parts with oil
cir cuiting. or grease before installation.
l Use a cover on the body, the seats and the floor to l When necessary, use a sealer on gaskets to prevent
protect them against damage and contamination. leakage.
l Handle brake fluid and antifreeze solution with care l Carefully observe all specifications for bolt and nut
as they can cause paint damage. torques.
l The use of proper tools, and the recommended l When service operation is completed, make a final
essential and available tools where specified, are check to be sure service was done properly and the
important for efficient and reliable performance of problem was corrected.
the service repairs.
VEHICLE IDENTIFICATION NUMBER SYSTEM
K P T P 0 A 1 9 S W P 122357
12~17.Production Serial Number

: 000001- 999999
11.Plant Code
P : PyongTaek Plant
10.Model Year
M : 1991
N : 1992
P : 1993
R : 1994
S : 1995
T : 1996
V : 1997
W : 1998
X : 1999
Y : 2000
9. Check Digit
Constant “S”
8. Engine Type
3 : 2299cc, In-line 4Cylinder, Diesel (OM601)
4 : 2874cc, In-line 5Cylinder, Diesel (OM602)
8 : 1998cc, In-line 4Cylinder, Gasoline (E20)
A : 2299cc, In-line 4Cylinder, Diesel (OM601)
B : 2874cc, In-line 5Cylinder, Diesel (OM602)
C : 2299cc, In-line 4Cylinder, Diesel (SY662LA)
D : 2874cc, In-line 5Cylinder, Diesel (SY662LA)
7. Restraint System
0 : NO Seat Belt,
1 : 3-Point Seat Belts, 2 : 2-Point Seat Belts
6. Trim Level
A : Standard, B : Deluxe, C : Super Deluxe
5. Body Type
0 : 5-Door
1 : 4-Door
2 : 3-Door
4. Line Models
P : Musso, LHD, R : Musso, RHD
3. Vehicle Type
T (Passengr Cars)
2. Name of Mamufacturer : P
1. Nation : K
Manufacturer’s Plate
1.Type Approval No. 2.Vehicle Identification Number.
Manufacturer’s Plate Location
Diesel Engine Gasoline Engine

Gasolind Engine Number Diesel Engine Number
162 990 1 0 012345 662 920 1 0 012345
Serial Number Serial Number
0 : Manual T/M 0 : Manual T/M

1 : Hydr - Auto Coupling 1 : Hydr - Auto Coupling
2 : Automatic T/M 2 : Automatic T/M
0 : Common 0 : Common
1 : Left - Hand Drive 1 : Left - Hand Drive
2 : Right - Hand Drive 2 : Right - Hand Drive
0 : MUSSO 910 : Non-Intercooler Engine

920 : Intercooler Engine
99 : 3.2L
97 : 2.3L 661 : 2299cc
94 : 2.0L 662 : 2874cc
ENGINE TYPE
Engine Number Location
Diesel Engine IL6 3200

The engine number is stamped on the cylinder block in The engine number is stamped on the lower rear side
front of injection pump. of the alternator.
VEHICLE LIFTING PROCEDURES

To raise the vehicle, place the lifting equipment only at
the points indicated. Failure to use these precise
positions may result in permanent vehicle body
deformation.
Many dealer service facilities and service stations are
equipped with automative hoists that bear upon some
parts of the frame in order to lift the vehicle. If any other
hoist method is used, take special care to avoid
damaging the fuel tank, the filter neck, the exhaust
system, or the underbody.
Vehicle Lifting Points
2300 DOHC
The engine number is stamped on the upper rear left-
hand side of the cylinder block.
Using Jack
(Rearward of Front Tire)
Using Jack
(Forward of Rear Tire)
SECTION 1
ENGINE
SECTION 1A1(M162 ENGINE)
GENERAL ENGINE INFORMATION

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A1-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-7
Engine Specifications . . . . . . . . . . . . . . . . . . 1A1-1 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A1-7
Component Locator . . . . . . . . . . . . . . . . . . 1A1-3 Engine Cranking at The
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-3 Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A1-8
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-4 Compression Pressure Test . . . . . . . . . . . . . 1A1-9
Performance Curve . . . . . . . . . . . . . . . . . . 1A1-5 Cylinder Pressure Leakage Test. . . . . . . . . 1A1-11
E32 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A1-5 General Information . . . . . . . . . . . . . . . . . 1A1-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A1-6 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A1-13
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A1-6 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A1-13
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application E32 Engine
Engine Model M162.990
Displacement (CC) 3199
Cylinder (Bore x Stroke) (mm) 89.9 x 84.0
Fuel Injection / Ignition System MSE 3.62S
Compression Ratio 10 : 1
Number of Cylinders 6
Camshaft Valve Arrangement DOHC
Camshaft Drive Type Chain-Driven
Max. Output (ps/rpm) 222 / 5500
Max. Torque (kg•m/rpm) 31.6 / 3750
Firing Order 1-5-3-6-2-4
Ignition Type Distributorless Double Ignition
Ignition Timing BTDC 8° ± 2°
Valve Timing Intake Open/Close ATDC 11° / ABDC 34°
Exhaust Open/Close BBDC 31° / BTDC 14°
Valve Clearance Adjustment Automatic Control
1A1-2 GENERAL ENGINE INFORMATION
ENGINE SPECIFICATIONS (Cont'd)

Application E32 Engine
Idle Speed (rpm) 700 ± 50
Fuel Injection Pressure (kg/cm²) 3-4
Oil Capacity (liter) 8.2
Lubrication Type Forced by Gear Pump
Oil Filter Type Full Flow with Paper Filter
Fuel Unleaded Gasoline
MSE 3.62S/3.53S (Motorsteuer Elektronik : German)
MSE : Engine Control Electronic
3.62S : 6 Cylinder Version
3.53S : 4 Cylinder Version
GENERAL ENGINE INFORMATION 1A1-3
COMPONENT LOCATOR
FRONT VIEW
1 HFM Sensor 12 Intake Manifold

2 Intake Air Duct 13 Connecting Rod
3 Resonance Flap 14 Exhaust Manifold
4 Cylinder Head Cover 15 Crankshaft
5 Exhaust Camshaft 16 Engine Mounting Bracket
6 Intake Camshaft 17 Starter
7 Cylinder Head 18 Crankcase
8 Spark Plug Connector 19 Oil Pump Sprocket
9 Valve Tappet 20 Oil Strainer
10 Injector 21 Oil Pan
11 Exhaust Valve 22 Drain Plug
SIDE VIEW
23 Camshaft Adjuster 27 Oil Pump Drive Chain

24 Cooling Fan and Viscous Clutch 28 Oil Return Pipe
25 Piston 29 Timing Chain
26 Flywheel of Drive Plate 30 Oil Pump
PERFORMANCE CURVE
E32 ENGINE
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 001 589 65 09 00

Torque Wrench Socket
001 589 76 21 00 119 589 01 09 00

Compression Pressure Spark Plug Wrench
Tester
DIAGNOSIS
OIL LEAK DIAGNOSIS 2. Operate the vehicle normal operating conditions as
directed in the kit.
Most fluid oil leaks are easily located and repaired by
3. Direct the light toward the suspected area. The dyed
visually finding the leak and replacing or repairing the
fluid will appear as a yellow path leading to the
necessary parts. On some occasions a fluid leak may
source.
be difficult to locate or repair. The following procedures
may help you in locating and repairing most leaks. Repairing the Leak
Finding the Leak Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
1. Identify the fluid. Determine whether it is engine oil,
determined n order for it to be repaired properly. If a
automatic transmission fluid, power steering fluid, etc.
gasket is replaced, but the sealing flange is bent, the
2. Identify where the fluid is leaking from. new gasket will not repair the leak. The bent flange must
2.1 After running the vehicle at normal operating be repaired also. Before attempting to repair a leak,
temperature, park the vehicle over a large sheet check for the following conditions and correct them as
of paper. they may cause a leak.
2.2 Wait a few minutes. Gaskets
2.3 You should be able to find the approximate
l The fluid level/pressure is too high.
location of the leak by the drippings on the
paper. l The crankcase ventilation system is malfunctioning.
3. Visually check around the suspected component. l The fasteners are tightened improperly or the threads
Check around all the gasket mating surfaces for are dirty or damaged.
leaks. A mirror is useful for finding leaks in areas that l The flanges or the sealing surface is warped.
are hard to reach. l There are scratches, burrs or other damage to the
4. If the leak still cannot be found, it may be necessary sealing surface.
to clean the suspected area with a degreaser, steam l The gasket is damaged or worn.
or spray solvent. l There is cracking or porosity of the component.
4.1 Clean the area well. l An improper seal was used (where applicable).
4.2 Dry the area.
Seals
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
l The crankcase ventilation system is malfunctioning.
4.4 After operating the vehicle, visually check the
suspected component. l The seal bore is damaged (scratched, burred or
4.5 If you still cannot locate the leak, try using the nicked).
powder or black light and dye method. l The seal is damaged or worn.
l Improper installation is evident.
Powder Method
l There are cracks in the components.
1. Clean the suspected area.
l The shaft surface is scratched, nicked or damaged.
2. Apply an aerosol-type powder (such as foot powder)
to the suspected area. l A loose or worn bearing is causing excess seal wear.
3. Operate the vehicle under normal operating
conditoins.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer's directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
ENGINE CRANKING AT THE FRONT OF CRANKSHAFT

Preceding Work : Removal of cooling fan
1 Vibration Damper Assembly 3 Bolt ................................................. 8.6 ± 0.9 Nm

2 Crankshaft Pulley
Notice
l Remove the negative ground cable before proceeding the work.
l Rotate the pulley in normal engine rotating direction when cranking.
Tools Required
000 589 10 99 01 Torque wrench
001 589 65 09 00 Socket
COMPRESSION PRESSURE TEST
1 Compression Pressure Tester 3 Adaptor

2 Diagram Sheet 4 Sealing Cone
Tools Required
001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench
Standard Service Data

Compression Ratio 10 : 1
Normal Engine Temperature 80°C
Normal Compression Pressure General Min. 10 bar, Max. 14 bar
Fuel Optimization Min. 6 bar, Max. 10 bar
Permissible Pressure Difference Between Individual Max. 1.5 bar
Cylinders
Measuring Procedure
1. Warm the engine up to normal operating temperature.
2. Remove the spark plugs.
3. Place the diagram sheet to compression pressure
tester.
4. Connect the adaptor to compression pressure tester
and install it into the spark plug hole.
5. Crank the engine approx. eight revolutions by using
the start motor.
6. Compare the measurements of compression
pressure tester with the specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.
Notice
l Discharge the combustion residues in the cylinders
before testing the compression pressure.
l Apply the parking brake before cranking the
engine.
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with

4 Vibration Damper Connecting Hose
Permissible Pressure Leakage

At Whole Engine Max. 25 %
At Valve and Cylinder Head Gasket Max. 10 %
At Piston and Piston Ring Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark OT (TDC) a (120°) b (240°)
Cylinder Number 1, 6 2, 5 3, 4
Universal Tool
Cylinder Pressure Leakage Tester Bosch, EFAW 210A
Sun, CLT 228
Leakage Test
2. Disconnect the negative battery cable.
4. Check the coolant level by opening the coolant surge tank
cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the scale
of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotating the

crankshaft.
9. Connect the connecting hose to tester and measure the

leakage volume after blowing up 5bar of compressed air.
Notice
Measure the leakage volume in the completely opening
condition of throttle valve by pulling the acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order : 1 - 5 - 3 - 6 - 2 - 4
11. Compare the leakage pressure with the specifications.
GENERAL INFORMATION
CLEANLINESS AND CARE Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
An automobile engine is a combination of many cables may result in damage to wire harness or other
machined, honed, polished and lapped surfaces with electrical parts.
tolerances that are measured in the ten-thousanths of
an inch. When any internal engine parts are serviced, ON-ENGINE SERVICE
care and cleanliness are important. A liberal coating of
enigne oil should be applied to friction areas during Caution: Disconnect the negative battery cable
assembly, to protect and lubricate the surfaces on initial before removing or installing any electrical unit, or
operation. Proper cleaning and protection of machined when a tool or equipment could easily come in
surfaces and friction areas is part of the repair contact with exposed electrical terminals.
procedure. This is considered standard shop practice Disconnecting this cable will help prevent personal
even if not specifically stated. injury and damage to the vehicle. The ignition must
also be in LOCK unless otherwise noted.
Whenever valve train components are removed for
service, they should be kept in order. They should be Notice: Any time the air cleaner is removed, the intake
installed in the same locations, and with the same mating opening should be covered. This will protect against
surfaces, as when they were removed. accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.
SECTION 1
ENGINE
SECTION 1A2(M161 ENGINE)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A2-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-8
Engine Specifications . . . . . . . . . . . . . . . . . . 1A2-1 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A2-8
Component Locator . . . . . . . . . . . . . . . . . . 1A2-3 Engine Cranking At The
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-3 Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A2-9
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-4 Compression Pressure Test . . . . . . . . . . . . 1A2-10
Performance Curve . . . . . . . . . . . . . . . . . . 1A2-5 Cylinder Pressure Leakage Test. . . . . . . . . 1A2-12
E23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-5 General Information . . . . . . . . . . . . . . . . . 1A2-14
E20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-6 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A2-14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A2-7 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A2-14
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A2-7
SPECIFICATIONS
Application E23 Engine E20 Engine
Engine Model M161.970 M161.940
Displacement (CC) 2295 1998
Cylinder (Bore x Stroke) (mm) 90.9 x 88.4 89.9 x 78.7
Fuel Injection / Ignition System MSE 3.53S ¬
Compression Ratio 10.4:1 9.6:1
Number of Cylinders 4 ¬
Camshaft Valve Arrangement DOHC ¬
Camshaft Drive Type Chain-Driven ¬
Max. Output (ps/rpm) 149 / 5500 135 / 5500
Max. Torque (kg•m/rpm) 22.4 / 4000 19.3 / 4000
Firing Order 1-3-4-2 ¬
Ignition Type Distributorless ¬
Ignition Timing BTDC 6° ± 2° ¬
Valve Timing Intake Open/Close ATDC 19.25° / ABDC 28.76° ATDC 13.15° / ABDC 13.57°
Exhaust Open/Close BBDC 20.62° / BTDC 15.08° BBDC 16.58° / BTDC 17.05°
Valve Clearance Adjustment Automatic Control ¬

Application E23 Engine E20 Engine
Idle Speed (rpm) 750 ± 50 ¬
Fuel Injection Pressure (kg/cm²) 3.2 - 4.2 ¬
Oil Capacity (liter) 7.5 ¬
Lubrication Type Forced by Gear Pump ¬
Oil Filter Type Full Flow with Paper Filter ¬
Fuel Unleaded Gasoline ¬
MSE 3.62S/3.53S (Motorsteuer Elektronik : German)

MSE : Engine Control Electronic
3.62S : 6 cylinder version
3.53S : 4 cylinder version
COMPONENT LOCATOR
FRONT VIEW
1 HFM Sensor 12 Intake Manifold

2 Intake Air Duct 13 Cylinder Head
3 Cylinder Head Cover 14 Exhaust Manifold
4 Ignition Coil 15 Dipstick Guide Tube and Gauge
5 Spark Plug Connector 16 Connecting Rod
6 Fuel Distributor 17 Crankshaft
7 Injector 18 Engine Mounting Bracket
8 Exhaust Camshaft 19 Starter
9 Intake Camshaft 20 Crankcase
10 Valve Tappet 21 Oil Pump Sprocket
11 Intake Valve 22 Oil Pan
SIDE VIEW
23 Camshaft Adjuster 29 Oil Pump Drive Chain

24 Oil Filler Cap 30 Oil Strainer
25 Engine Hanger Bracket 31 Oil Pump
26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate
27 Oil Filter 33 Piston
28 Timing Chain
PERFORMANCE CURVE
E23 ENGINE
E20 ENGINE
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 001 589 65 09 00

001 589 76 21 00 119 589 01 09 00

Compression Pressure Spark Plug Wrench
Tester
DIAGNOSIS
OIL LEAK DIAGNOSIS Black Light and Dye Method
Most fluid oil leaks are easily located and repaired by A dye and light kit is available for finding leaks, Refer to
visually finding the leak and replacing or repairing the the manufacturer's directions when using the kit.
necessary parts. On some occasions a fluid leak may 1. Pour the specified amount of dye into the engine oil
be difficult to locate or repair. The following procedures fill tube.
may help you in locating and repairing most leaks. 2. Operate the vehicle normal operating conditions as
Finding the Leak directed in the kit.
1. Identify the fluid. Determine whether it is engine oil, 3. Direct the light toward the suspected area. The dyed
automatic transmission fluid, power steering fluid, etc. fluid will appear as a yellow path leading to the
source.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating Repairing the Leak
temperature, park the vehicle over a large sheet Once the origin of the leak has been pinpointed and
of paper. traced back to its source, the cause of the leak must be
2.2 Wait a few minutes. determined n order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
new gasket will not repair the leak. The bent flange must
location of the leak by the drippings on the
be repaired also. Before attempting to repair a leak,
paper.
check for the following conditions and correct them as
3. Visually check around the suspected component. they may cause a leak.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that Gaskets
are hard to reach. l The fluid level/pressure is too high.
4. If the leak still cannot be found, it may be necessary l The crankcase ventilation system is malfunctioning.
to clean the suspected area with a degreaser, steam l The fasteners are tightened improperly or the threads
or spray solvent. are dirty or damaged.
4.1 Clean the area well. l The flanges or the sealing surface is warped.
4.2 Dry the area. l There are scratches, burrs or other damage to the
4.3 Operate the vehicle for several miles at normal sealing surface.
operating temperature and varying speeds. l The gasket is damaged or worn.
4.4 After operating the vehicle, visually check the l There is cracking or porosity of the component.
suspected component.
l An improper seal was used (where applicable).
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method. Seals
Powder Method
l The crankcase ventilation system is malfunctioning.
1. Clean the suspected area.
l The seal bore is damaged (scratched, burred or
2. Apply an aerosol-type powder (such as foot powder)
nicked).
to the suspected area.
l The seal is damaged or worn.
conditoins. l Improper installation is evident.
4. Visually inspect the suspected component. You l There are cracks in the components.
should be able to trace the leak path over the white l The shaft surface is scratched, nicked or damaged.
powder surface to the source. l A loose or worn bearing is causing excess seal wear.
ENGINE CRANKING AT THE FRONT OF CRANKSHAFT

1 Torque Wrench 4 Center Bolt (M18 ´ 55, 1piece)

2 Socket ..................................... 1st Step 200Nm + 20Nm
3 Vibration Damper Ass'y 2nd Step 90° + 10°
Notice
l Remove the negative ground cable before proceeding the work.
l Rotate the pulley in normal engine rotating direction when cranking.
Tools Required
000 589 10 99 01 Torque Wrench
001 589 65 09 00 Socket
1 Compression Pressure Tester 3 Adaptor

2 Diagram Sheet 4 Sealing Cone
Tools Required
001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench
Standard Service Data

Compression Ratio 10.4, 9.6
Normal Engine Temperature 80°C
Normal Compression Pressure E23 Engine(e = 10.4) Min. 11 bar, Max. 15 bar
E20 Engine(e = 9.6) Min. 10.5 bar, Max. 14 bar
Permissible Pressure Difference Between Individual Max. 1.5 bar
Cylinders
Measuring Procedure
3. Place the diagram sheet to compression pressure
tester.
4. Connect the adaptor to compression pressure tester
and install it into the spark plug hole.
5. Crank the engine approx. eight revolutions by using
the start motor.
6. Compare the measurements of compression
pressure tester with the specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.
Notice
l Discharge the combustion residues in the cylinders
before testing the compression pressure.
l Apply the parking brake before cranking the
engine.
3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with

5 Vibration Damper Connecting Hose
Permissible Pressure Leakage

Cylinder Number By Mark On Vibration Damper At TDC

TDC Mark OT (TDC) UT (BDC : 180°)
Cylinder Number 1, 4 2, 3
Universal Tool
Cylinder Pressure Leakage Tester Bosch EF AW 210A
Sun, CLT 228
Leakage Test
2. Disconnect the negative battery cable.
4. Check the coolant level by opening the coolant surge tank
cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the scale
of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotating the

crankshaft.
9. Connect the connecting hose to tester and measure the

leakage volume after blowing up 5bar of compressed air.
Notice
Measure the leakage volume in the completely opening
condition of throttle valve by pulling the acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order : 1 - 3 - 4 - 2
11. Compare the leakage pressure with the specifications.
GENERAL INFORMATION
CLEANLINESS AND CARE ON-ENGINE SERVICE
An automobile engine is a combination of many Caution: Disconnect the negative battery cable be-
machined, honed, polished and lapped surfaces with fore removing or installing any electrical unit, or
tolerances that are measured in the ten-thousanths of when a tool or equipment could easily come in con-
an inch. When any internal engine parts are serviced, tact with exposed electrical terminals. Disconnect-
care and cleanliness are important. A liberal coating of ing this cable will help prevent personal injury and
enigne oil should be applied to friction areas during damage to the vehicle. The ignition must also be in
assembly, to protect and lubricate the surfaces on initial LOCK unless otherwise noted.
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair Notice: Any time the air cleaner is removed, the intake
procedure. This is considered standard shop practice opening should be covered. This will protect against
even if not specifically stated. accidental entrance of foreign material, which could
service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when they were removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other
electrical parts.
SECTION 1
ENGINE
SECTION 1A3(OM600 ENGINE)

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A3-1 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A3-9
Engine Specifications . . . . . . . . . . . . . . . . . . 1A3-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1A3-10
Sectional View . . . . . . . . . . . . . . . . . . . . . . 1A3-3 Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . 1A3-10
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-3 Compression Pressure Test . . . . . . . . . . . . 1A3-11
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-5 Cylinder Pressure Leakage Test. . . . . . . . . 1A3-13
Performance Curve . . . . . . . . . . . . . . . . . . 1A3-7 General Information . . . . . . . . . . . . . . . . . 1A3-15
OM662LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-7 Cleanliness and Care . . . . . . . . . . . . . . . . . 1A3-15
OM661LA Engine . . . . . . . . . . . . . . . . . . . . . 1A3-8 On-Engine Service . . . . . . . . . . . . . . . . . . . 1A3-15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A3-9
SPECIFICATIONS
Application OM662LA OM661LA
Engine Type Four-Stroke Diesel Four-Stroke Diesel
Displacement (CC) 2874 2299
Cylinder (Bore x Stroke) (mm) 89 x 92.4 89 x 92.4
Fuel Injection / Ignition System PES 5 M55 C320 RS 168 PES 5 M55 C320 RS 167
Compression Ratio 22:1 22:1
Number of Cylinders 5 4
Camshaft Valve Arrangement SOHC SOHC
Camshaft Drive Type Chain-Drive Chain-Drive
Max. Output (ps/rpm) 120 / 4000 101 / 4000
Max. Torque (kg•m/rpm) 25.5 / 4000 21.5 / 2400
Firing Order 1-2-4-5-3 1-3-4-2
Injection Timing BTDC 18°± 10° BTDC 18°± 10°
Valve Timing Intake Open/Close ATDC 11.33° / ABDC 17° ATDC 11.33° / ABDC 17°
(at 2mm lift) Exhaust Open/Close BBDC 28° / BTDC 15.25° BBDC 28° / BTDC 15.25°
Valve Clearance Adjustment Automatic Control Automatic Control

Application OM 662 LA OM661LA
Idle Speed (rpm) 720 - 820 750 - 850
Fuel Injection Pressure (bar) 135 - 143 135 - 143
Oil Capacity (liter) 8.0 - 9.5 6.5 - 8.0
Lubrication Type Forced by Gear Pump Forced by Gear Pump
Oil Filter Type Combined Full-Flow and Partial Flow Combined Full-Flow and Partial Flow
Filter Filter
Fuel Diesel Diesel
SECTIONAL VIEW
OM662LA ENGINE
Front View
Side View
OM661LA ENGINE
Front View
Side View
PERFORMANCE CURVE
OM662LA ENGINE
rpm
OM661LA ENGINE
rpm
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 001 589 65 09 00

001 589 76 21 00 001 589 73 21 00

Compression Pressure Hand Vacuum Pump
Tester
DIAGNOSIS
OIL LEAK DIAGNOSIS 1. Pour the specified amount of dye into the engine
oil fill tube.
Most fluid oil leaks are easily located and repaired by
2. Operate the vehicle normal operating conditions
visually finding the leak and replacing or repairing the
as directed in the kit.
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following 3. Direct the light toward the suspected area. The
procedures may help you in locating and repairing dyed fluid will appear as a yellow path leading to
most leaks. the source.
Finding the Leak Repairing the Leak

1. Identify the fluid. Determine whether it is engine Once the origin of the leak has been pinpointed and
oil, automatic transmission fluid, power steering traced back to its source, the cause of the leak must
fluid, etc. be determined n order for it to be repaired properly. If
a gasket is replaced, but the sealing flange is bent,
2. Identify where the fluid is leaking from.
the new gasket will not repair the leak. The bent flange
2.1 After running the vehicle at normal operating must be repaired also. Before attempting to repair a
temperature, park the vehicle over a large leak, check for the following conditions and correct
sheet of paper. them as they may cause a leak.
2.2 Wait a few minutes.
Gaskets
location of the leak by the drippings on the l The fluid level/pressure is too high.
paper. l The crankcase ventilation system is malfunctioning.
3. Visually check around the suspected component. l The fasteners are tightened improperly or the
Check around all the gasket mating surfaces for threads are dirty or damaged.
leaks. A mirror is useful for finding leaks in areas l The flanges or the sealing surface is warped.
that are hard to reach. l There are scratches, burrs or other damage to the
4. If the leak still cannot be found, it may be sealing surface.
necessary to clean the suspected area with a l The gasket is damaged or worn.
degreaser, steam or spray solvent.
l There is cracking or porosity of the component.
4.1 Clean the area well.
l An improper seal was used (where applicable).
4.2 Dry the area.
4.3 Operate the vehicle for several miles at
Seals
normal operating temperature and varying l The fluid level/pressure is too high.
speeds. l The crankcase ventilation system is malfunctioning.
4.4 After operating the vehicle, visually check the l The seal bore is damaged (scratched, burred or
suspected component. nicked).
4.5 If you still cannot locate the leak, try using the l The seal is damaged or worn.
powder or black light and dye method. l Improper installation is evident.
Powder Method l There are cracks in the components.
1. Clean the suspected area. l The shaft surface is scratched, nicked or damaged.
2. Apply an aerosol-type powder (such as foot l A loose or worn bearing is causing excess seal
powder) to the suspected area. wear.
conditions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer
to the manufacturer's directions when using the kit.
1 Test Adapter
2 Flexible Connector
3 Compression Pressure Recorder
Service Data
Normal Compression Pressure 28bar
Minimum Compression Pressure Approx.18bar
Permissible Pressure Difference Between Individual Cylinders Max. 3bar
lEngine at normal operating temperature of 80°C
Tools Required
000 589 65 09 00 Socket
001 589 73 21 00 Hand Vacuum Pump
Compression Pressure Measurement
Notice
Ensure that no gear is engaged and that the vehicle is
protected from rolling.
1. Run the engine to be the coolant temperature 80°C.
2. Remove the fuel injection nozzle.
Socket Wrench Insert 001 589 65 09 00

3. Install the test adapter (1) and connect the flexible
connector (2) to the compression pressure recorder.
Compression Pressure Recorder 001 589 76 21 00
4. Disconnect the vacuum line from the stop unit and

connect the hand vacuum pump to the stop unit.
5. Pump the hand vacuum pump and make the fuel injection
pump in stop position.
Operating Pressure Approx. 500bar
Hand Vacuum Pump 001 589 73 21 00
6. Using a starter motor, crank the engine 8 revolutions.

7. Measure the remaining cylinder compression pressure
in the same manner and compare it with service data.
Notice
If out of standard, do cylinder pressure leakage test.
8. Remove the compression pressure recorder.
9. Install the fuel injection nozzle.
1 Connector
2 Connection Piece
3 Connection Hose
Permissible Pressure Leakage (Engine at Normal Operating Temperature of 80°C)

Commercial Tools
Cylinder Pressure Leakage tester BOSCH, EFAW 210 A or SUN CLT 228
Connection Piece BOSCH order no. 1 687 010 016
Leakage Test
1. Run the engine to be the coolant temperature 80°C.
2. Remove the fuel injection nozzle.
3. Open the coolant subtank cap.
4. Check the coolant level and replenish if necessary.
5. Open the oil filler cap.
6. Remove the air cleaner cover and element.
7. Position the piston at TDC.
8. Install the connector (1) and connection piece (2).
9. Calibrate the tester and connect the connection hose
(3)
10. Pressurize with compressed air and compare the
pressure changes with permissible pressure leakage.
11. If permissible pressure leakage is out of standard, check
followings :
- Intake and exhaust lines.
- Sounds in oil filler area.
- Air bubbles in radiator coolant.
12. Do pressure leakage test for the remaining cylinders
according to the firing order.
l OM 662LA Engine : 1-2-4-5-3
l OM 661LA Engine : 1-3-4-2
13. Remove the tester.
14. Close the coolant pressure cap and oil filler cap.
15. Install the air cleaner element and cover.
GENERAL INFORMATION
CLEANLINESS AND CARE Battery cables should be disconnected before any
major work is performed on the engine. Failure to
An automobile engine is a combination of many disconnect cables may result in damage to wire
machined, honed, polished and lapped surfaces with harness or other electrical parts.
tolerances that are measured in the ten-thousanths
of an inch. When any internal engine parts are ON-ENGINE SERVICE
serviced, care and cleanliness are important. A liberal
coating of enigne oil should be applied to friction areas Caution: Disconnect the negative battery cable
during assembly, to protect and lubricate the surfaces before removing or installing any electrical unit,
on initial operation. Proper cleaning and protection or when a tool or equipment could easily come in
of machined surfaces and friction areas is part fo the contact with exposed electrical terminals.
repair procedure. This is considered standard shop Disconnecting this cable will help prevent
practice even if not specifically stated. personal injury and damage to the vehicle. The
ignition must also be in LOCK unless otherwise
noted.
service, they should be kept in order. They should be
installed in the same locations, and with the same Notice: Any time the air cleaner is removed, the intake
mating surfaces, as when they were removed. opening should be covered. This will protect against
accidental entrance of foreign material, which could
SECTION 1B1
M162 ENGINE MECHANICAL

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B1-2 Camshaft Timing Position . . . . . . . . . . . . . . 1B1-64
Fastener Tightening Specifications . . . . . . . . 1B1-2 Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B1-67
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B1-4 Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B1-71
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B1-4 Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B1-72
Maintenance and Repair . . . . . . . . . . . . . . 1B1-8 Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B1-75
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B1-8 Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B1-80
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B1-8 Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B1-81
Crankcase Ventilation System . . . . . . . . . . 1B1-16 Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B1-82
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-18 Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B1-83
Power Steering Pump and A/C Bracket . . . 1B1-19 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-85
Hydraulic Engine Mounting Insulator . . . . . . 1B1-22 Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B1-88
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-25 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-90
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B1-27 Engine Oil Specification . . . . . . . . . . . . . . . 1B1-92
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B1-29 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-93
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B1-31 Engine Oil and Oil Filter Element . . . . . . . . 1B1-95
Cylinder Head Front Cover . . . . . . . . . . . . . 1B1-33 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-97
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B1-35 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-99
Timing Gear Case Cover . . . . . . . . . . . . . . 1B1-38 Oil Pressure Relief Valve . . . . . . . . . . . . . 1B1-101
Crankshaft Sealing Rear Cover . . . . . . . . . 1B1-40 Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B1-102
Belt Pulley and Vibration Damper . . . . . . . . 1B1-42 Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B1-103
Crankshaft Front Radial Seal . . . . . . . . . . . 1B1-45 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B1-104
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B1-46 Oil Gallery in Crankcase . . . . . . . . . . . . . . 1B1-104
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-47 Oil Gallery in Cylinder Head . . . . . . . . . . . 1B1-106
Flywheel / Driven Plate . . . . . . . . . . . . . . . . 1B1-53 Core Plugs in Crankcase . . . . . . . . . . . . . 1B1-109
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B1-55 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B1-111
Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B1-58 Crankcase Mating Surface . . . . . . . . . . . . 1B1-113
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B1-59 Cylinder Head Mating Surface . . . . . . . . . 1B1-115
1B1-2 M162 ENGINE MECHANICAL
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application N·
·m
Power Steering Hydraulic Lines 35 - 40
A/C High Pressure and Liquid Hose 10 - 15
Radiator Support Menber Bolt 5 - 10
Fuel Supply and Return Hose to Fuel Distributor 21 - 25
Exhaust Manifold and Pipe 30
Propeller Shaft to Transmission 56 - 66
Engine Mounting Nut 50 - 60
Alternator Carrier Bolt 10 - 15
Belt Pulley Bolt 41.5 - 49.5
Steering Pump Bolt 22.5 - 27.5
A/C Bracket Bolt 22.5 - 27.5
Intake Air Duct Bolt 9 - 11
Ignition Cable Cover Bolt 9 - 11
Cylinder Head Cover Bolt 22.5 - 27.5
Camshaft Adjuster Bolt 9 - 11
Cylinder Head Front Cover Bolt 22.5 - 27.5
Flange Bolt in Exhaust Camshaft Sprocket 10
+90°
Cylinder Head Bolt 55
+90°
+90°
Cooling Fan Bracket Bolt 22.5 - 27.5
Timing Gear Case Cover Bolt M8 22.5 - 27.5
M6 9 - 10
Crankshaft Rear Cover Bolt 9 - 10
Vibration Damper Center Bolt 200
+90°
Connecting Rod Bearing Cap Bolt 40
+90°
Flywheel Stretch Bolt 45
+90°
Amarture Bolt in Flywheel 35
Ring and Seal Cover Nut in Flywheel 9 - 11
Sprocket Bolt to Exhaust Camshaft 20
+90°
Camshaft Adjuster Flange Bolt 20
+90°
Intake Flange Shaft Bolt 20 / + 90°
Exhaust Camshaft Sprocket Bolt 20 / + 90°
Camshaft Bearing Cap Bolt 22.5 - 27.5
M162 ENGINE MECHANICAL 1B1-3
FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application N·
·m
Exhaust Camshaft Sproket Bolt 20 / +90°
Chain Tensioner Screw Plug 40
Chain Tensioner Assembly 72 - 88
Exhaust Camshaft Sprocket to Camshaft 20 / +90°
Oil Pump Sprocket Bolt 25 - 35
Tensioning Device Bolt 22.5 - 27.5
Water Pump Pulley 22.5 - 27.5
Upper Intake Manifold Bolt 22.5 - 27.5
Lower Intake Mainfold Bolt 22.5 - 27.5
Flange Bolt to Exhaust Mainfold 30
Exhaust Mainfold Nut to Stud Bolt 26 - 34
Rivet Nut in Exhuast Mainfold Hole 30
Pre-silencer Bolt 8 - 10
Oil Drain Plug 25
Oil Filter Cover 25
Oil Filter Bolt 22.5 - 27.5
Oil Pump Drive Sprocket Bolt 29 - 35
Oil Pump Mounting Bolt 22.5 - 27.5
Oil Strainer Bracket Bolt 9 - 11
Oil Pressure Relief Valve Screw Plug 50
Oil Dipstick Guide Tube Bolt 9 - 11
Oil Gallery Screw Plug 15
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 000 589 40 37 00

Torque Wrench Hose Clamp
112 589 00 72 00 000 589 72 21 00

Oil Extractor Torque Wrench
001 589 66 21 00 124 589 15 21 00

Torque Wrench Radiator Cap
Testing Unit
000 589 01 10 00 116 589 02 34 00

Box Wrench Insert Screw-Fixed Pin
SPECIAL TOOLS TABLE (Cont’d)
104 589 01 01 00 111 589 01 59 00

Spanner Supporting Bar
111 589 18 61 00 111 589 25 63 00

Lever Pusher Thrust Piece
116 589 06 63 00 104 589 00 37 00

Magnetic Finger Pliers
119 589 00 43 00 000 589 58 43 00

Drift Chain Assembly
116 589 20 33 00 601 589 03 43 00

Sliding Hammer Sleeve
602 589 00 40 00 103 589 00 33 00

Engine Lock Puller
001 589 65 09 00 000 589 88 33 00

Socket Wrench Insert Puller
001 589 74 21 00 000 589 04 14 00

Torque Wrench Clamping Strap
103 589 01 63 00 615 589 01 33 00

Rivet Set Caulking Bolt
103 589 02 09 00 102 589 12 15 00

Oil Filter Drift
Socket Wrench
102 589 00 15 00 601 589 03 14 00

Drift Sleeve
000 589 51 37 00 001 589 72 21 00

Clamping Strap Torque Wrench

ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Tools Required
000 589 40 37 00 Hose Clamp
112 589 00 72 00 Oil Extractor
Removal & Installation Procedure
1. Disconnect the negative terminal of battery.
2. Remove the hood.
3. Remove the under cover.
Installation Notice
Tightening Torque 28 - 47 Nm
4. Disconnect the coupling of HFM sensor and remove the air

cleaner cross pipe.
5. Remove the air cleaner cover. Remove the mounting bolts

and air cleaner housing and element assembly.
6. Loosen the radiator drain cock and drain the coolant.

Notice
Open the coolant reservoir cap.
7. Loosen the cylinder block drain plug and then drain the
coolant completely.
Installation Notice
Tightening Torque 30 Nm
Notice
Replace the seal before installation of the drain plug.
8. Remove the cooling fan shroud.
9. Disconnect the each hose from radiator.
10. Remove the upper mounting bolts of radiator and then

remove the radiator.
11. Remove the hydraulic pipe of power steering.
Notice
Completely drain the oil.
12. Discharge the refrigerant from A/C system, and disconnect

the discharge pipe and suction pipe from the compressor.
13. Remove the acceleration control cable and automatic

transmission pressure cable.
14. Remove the fuel feed and return line.

Notice
Before removing the fuel lines, release the pressure in the
fuel system.
Installation Notice
15. Remove the automatic transmission dipstick guide tube.
16. Disconnect the wire of alternator.
17. Disconnect the wire of starter motor and remove the starter
motor.
18. Disconnect the engine main harness ground.
19. Disconnect the engine ground wire.

20. Disconnect following sensors connector.
l HFM sensor.
l Coolant temperature sensor.
l 2 knock sensors.
l Camshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition
coil connector.
22. Remove the harness cover and disconnect the 6 injection
valve connectors. Disconnect the main harness
23. Separate the hose toward engine from canister purge

solenoid valve.
24. Remove the automatic transmission oil cooler line.

25. Separate the vacuum hose for brake booster.
26. Separate the other vacuum hoses.
27. Remove the propeller shaft from the front axle.

Installation Notice
28. By rotating the crankshaft from the front of engine, remove

the 6 torque converter mounting bolts from the engine
ring gear plate.
29. Remove the exhaust manifold and exhaust pipe.

Installation Notice
30. Remove the transmission mounting bolts and separate
the transmission from the engine.
Installation Notice
31. Remove the bolts for engine mounting bracket.

Installation Notice
32. Hook the chain to the bracket of engine and by using a

hoist or crane, carefully separate the engine assembly
from the vehicle.
33. Installation should follow the removal procedure in the
reverse order.
CRANKCASE VENTILATION SYSTEM
1 Crankcase 13 Intake Air Duct (Cross Pipe)

2 Air Admission Port in Crankcase 14 Cylinder Head Cover
3 Oil Drain Port 15 Oil Separator
4 Filter 16 Oil Separator
5 Gasket 17 Air Admission and Vent Connection
6 A/C Bracket 18 Air Admission and Vent Connection
7 Oil Drain Pipe 19 Throttle Valve
8 Oil Pan 20 Vent Line
9 Air Admission Line A Fresh Air
10 Vent Line B Blowby Gas in Partial Load
11 Restriction Hole (Diameter = 2 mm) C Blowby Gas in Full Load
12 Intake Manifold
Operation at Idling and Mid-Load
l It show that the throttle valve (19) is closed or very partially
opened and the vacuum pressure in intake manifold is high.
The blowby gas in the crankcase in partial load flows into
the intake manifold through the vent line (20) after passing
the air conditioner bracket (6) and the filter (4). The air
reentered into the intake manifold will be dilluted on the flow
through the restriction hole (11) in the vent line (10).
The circulated engine oil is separated at the air conditioner
bracket (6) and then returns into the oil pan through the
drain pipe (7).
The vacuum pressure generated at the crankcase sucks
fresh air from intake air line(13) through the air admission
and vent connection (17,18).
The fresh air prevents engine oil from being contami-nated
and the air admission and vent connection (17,18) is
designed to control the rapid pressure changes in intake
air line (13).
Operation at Full-Load
l The throttle valve (19) is fully opened.
All the blowby gases flow into the intake air duct (13) after
passing through the oil separator (15,16) of the cylinder
head cover (14) when fully loaded. This dilluted air will be
supplied to the combustion chamber through the intake
manifold (12).
ALTERNATOR
1 Nut (M8) ......................................... 22.5-27.5 Nm 4 Bolt (M8 x 70, 1 piece) ................... 22.5-27.5 Nm
2 Bolt (M8 x 30, 3 pieces) ................. 22.5-27.5 Nm 5 Bolt (M8 x 75, 1 piece) ................... 22.5-27.5 Nm
3 Bolt (M8 x 40, 1 piece) ................... 22.5-27.5 Nm

1. Remove the drive belt.
2. Remove the alternator.
3. Unscrew the alternator carrier bolts and remove the carrier.
Installation Notice

reverse order.
POWER STEERING PUMP AND A/C BRACKET

Preceding Work : Removal of cooling fan and shroud
1 Vent Hose 8 A/C Bracket

2 Bolt (M8 x 91, 2 pieces) ................. 22.5-27.5 Nm 9 Gasket ................................................... Replace
3 Power Steering Pump 10 Bracket
4 Bolt (M8 x 105, 4 pieces) ............... 22.5-27.5 Nm 11 Bolt (M8 x 22, 2 pieces) ................. 22.5-27.5 Nm
5 Washer 12 Tensioning Pulley
6 A/C Compressor 13 Nut ................................................. 40.5-49.5 Nm
7 Bolt (M8 x 40, 3 pieces,
M8 x 95, 2 pieces) .......................... 22.5-27.5 Nm
1. Remove the belt pulley.
Installation Notice
Tightening Torque 40.5 - 49.5 Nm
Notice
Pull the tensioning pulley clockwise as shown in the figure.
2. Disconnect the hydraulic pipe of the power steering pump

and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump.

Installation Notice
4. Remove the compressor after disconnecting the wiring

connector and refrigerant pipe of A/C compressor.
Notice
Discharge all the refrigerant before removing the pipes.
5. Disconnect the vent hose from the A/C bracket.
6. Unscrew all the mounting bolts (arrows) and remove the

A/C bracket and the gasket.
Installation Notice
7. Clean the sealing surface.

8. Replace the gasket with new one.
reverse order.
10. Check the oil leakage by operating the engine after
installation.
HYDRAULIC ENGINE MOUNTING INSULATOR

Service Data
Sectional View
1 Rubber Body 9 Lower Orifice

2 Brackek 10 Upper Orifice
3 Core 11 Diaphram
4 Lower Bolt 12 Cover Plate
5 Rubber Plunger 13 Upper Bolt
6 Plunger Plate 14 Flange Bolt
7 Rubber 15 Rivet
8 Plate 16 Fluid
1 Upper Nut
2 Hydraulic Installor ................. 62-93 Nm
3 Lower Nut ............................. 28-47 Nm
Removal and Installation Procedure

1. Unscrew the upper nut(1) on engine mounting and remove
the engine.
Installation Notice
2. Unscrew the lower nut(3) and remove the hydraulic engine

mounting insulator.
Installation Notice
Notice
If the insulator is spotted with oil, replace the hydraulic
insulator assembly.
reverse order.
POLY V - BELT
1 Poly V-belt 2 Belt Tensioning Pulley

1. Release the belt tension by turning the belt tensioning pulley
nut clockwise.
2. Remove the poly v-belt.
Notice
Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley
clockwise.
Poly V-Belt Arrangement
1 Belt Tensioning Pulley 5 Alternator Pulley

2 Crankshaft Belt Pulley 6 Idler
3 A/C Compressor Pulley 7 Power Steering Pump Pulley
4 Cooling Fan Pulley 8 Cooling Fan and Water Pump Pulley
TENSIONING DEVICE
Preceding Work : Removal of poly v-belt
1 Belt (L = 2245) 3 Water Pump Pulley

2 Bolt Combi(M8 x 14, 3 pieces) + Washer 4 Nut
....................................................... 22.5-27.5Nm 5 Tensioning Pulley

2. Remove the tensioning pulley by turning its mounting nut
counter clockwise as shown in figure.
Installation Notice
3. Remove the 3 bolts (2) and remove the water pump pulley
(arrow).
Installation Notice
4. Remove the mounting bolts(M8 x 30, 3 pieces) at the

tensioning device, and remove the tensioning device (arrow).
Installation Notice

reverse order.
POLY V - BELT INSPECTION

l Make marks on the belt with chalk.
l Rotate the engine and check the belt for damage.
Notice
If one of the following types of damages is found, replace
the belt.
1. Rubber lumps in the base of rib.

2. Dirt or grit ingrained.
3. Pointed rib.
4. Belt cord visible in the base of rib.
5. Cord torn out at the side.

6. Outer cords frayed.
7. Rib detached from the base of belt.
8. Splits across the rib.

9. Sections of rib torn out.
10. Splits across several ribs.
11. Splits across the back of the belt.

CYLINDER HEAD COVER
1 Ignition Cable Dust Cover 6 Cylinder Head Cover

2 Bolt (M6 x 65, 8 pieces) ......................... 9-11 Nm 7 Gasket ................................................... Replace
3 Bolt (M6 x 50, 4 pieces) ......................... 9-11 Nm 8 Spart Plug Hole Seal .............................. Replace
4 Spacer Sleeve 9 Camshaft Seal ....................................... Replace
5 Thrust Piece
Composition of The Cylinder Head Cover Bolts
A. M6 x 50, 4 Pieces - Bolts + Washers

B. M6 x 65, 8 Pieces - Bolts + Washers
1. Remove the intake air duct.
Installation Notice
2. Remove the ignition cable cover.

Installation Notice
Notice
Unscrew the seven (M6 x 60) bolts and remove the ignition
cable cover.
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2,3) and remove the head cover and
the gasket.
Installation Notice
Notice
Replace the gasket with a new one if necessary.
reverse order.
6. Check for oil leaks by operating the engine.
CYLINDER HEAD FRONT COVER

Preceding Work : Removal of cylinder head cover
Removal of coolant connection fitting
1 Camshaft Position Sensor 5 Bolt (M8 x 80, 3 pieces) ................. 22.5-27.5 Nm

2 Magnet Assembly 6 Front Cover
3 Upper Guide Rail 7 Rubber Gasket ...................................... Replace
4 Bolt (M6 x 60, 3 pieces) ................. 22.5-27.5 Nm 8 Bolt (M6 x 16, 3 pieces) ......................... 9-11 Nm

1. Remove the magnet assembly.
Installation Notice
2. Remove the cylinder head front cover (6).
Installation Notice
Apply the sealant at the mating surface of the cylinder head

and the front cover.
3. Remove the upper guide rail pin and the guide rail (3).
Installation Notice
Install it while the chain tensioner is loose.
4. Remove the gasket (arrow).

Installation Notice
Replace the gasket with new one and apply the sealant.
reverse order.
CYLINDER HEAD
Removal of cylinder head front cover
Removal of upper intake manifold
1 Cylinder Head Bolt (14 pieces) 4 Exhaust Camshaft Sprocket

.................................................... 1st step 55 Nm 5 Cylinder Head
2nd step 90° 6 Gasket ................................................... Replace
3rd step 90° 7 Dowel Sleeve
2 Washers (14 pieces)
3 Flange Bolts (3 pieces) ................ 1st step 20 Nm
2nd step 90°
Tools Required
000 589 01 10 00 Box Wrench Insert
116 589 02 34 00 Screw-fixed Pin
116 589 20 33 00 Sliding Hammer

1. Rotate the crankshaft so that the piston of number 1 cylinder
is at TDC.
Notice
Rotate the crankshaft in the normal engine direction.
2. Put the alignment marks (arrows) on the timing chain and
camshaft sprocket.
3. Drain the coolant from the crankcase.
4. Remove the three flange bolts in the exhaust camshaft

sprocket.
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
Do not reuse the removed bolts.
5. Separate the chain from the camshaft sprockrt.

Notice
Be careful not to drop the chain into the timing case.
6. Remove the guide rail fixing pin from the cylinder head using
the sliding hammer (01) and the threaded pin (02).
Sliding Hammer 116 589 20 33 00

Threaded Pin 116 589 02 34 00
7. Remove the cylinder head bolts in numerical order.

Installation Notice
1st step 55 Nm
Tightening Torque 2nd step 90°
3rd step 90°
Box Wrench Insert 000 589 01 10 00
8. Check the length of the cylinder head bolt.

Installation Notice
New 160 ± 0.8 mm

Length (L)
Max. 162 ± 0.7 mm
l Replace the bolt if the measured length exceed the

max. length.
l Apply the oil to the thread surface of bolt.
9. Carefully remove the cylinder head and check the mating

surface.
reverse order.
TIMING GEAR CASE COVER

Preceding Work : Removal of cylinder head front cover
Removal of alternator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper
1 Bolt (M8 x 60, 3 pieces) ................. 22.5-27.5 Nm 6 Seal

2 A/C Bracket 7 Timing Gear Case Cover
3 Bolt (M8 x 65, 3 pieces) ................. 22.5-27.5 Nm 8 Roll Pin
4 Bolt (M8 x 40, 1 piece) ................... 22.5-27.5 Nm 9 Bolt (M6 x 22, 6 pieces) ......................... 9-11 Nm
5 Bolt (M8 x 60, 1 piece) ................... 22.5-27.5 Nm

camshaft sprocket.
2. Unscrew the A/C bracket bolts (1) and remove the bracket.
Installation Notice
3. Remove the cooling fan and the viscous clutch. Unscrew
the three bolts from the cooling fan bracket and remove the
bracket (arrows).
Installation Notice
4. Remove the timing gear case cover after unscrewing the

bolts (3) and (4) from the timing gear case cover and the
bolt (9) from the oil pan.
Notice
Be careful not to damage the oil pan gasket.
Installation Notice
Bolt (3,4) 22.5 - 27.5 Nm

Tightening Torque
Bolt (9) 9 - 11 Nm
l Apply the sealant after cleaning the timing gear case

cover surface.
l Be careful not to stain the oil chamber of chain tensioner
with the sealant.

reverse order.
6. Warm up the engine and check for oil leaks.
CRANKSHAFT SEALING REAR COVER

Preceding Work : Removal of the automatic transmission drive plate
1 Bolt (M6 x 20, 6 pieces) ......................... 9-11 Nm 4 Sleeve

2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......................... 9-11 Nm
3 Rear Cover 6 Washer
Tools Required
601 589 03 43 00 Sleeve

1. Unscrew the bolts (1) and (5) and remove the closing cover
by pulling the rear cover lug (arrows).
Notice
2. Clean the sealing surface of the crankcase and the rear

sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
Notice
Do not use the grease.
6. Using the special tool, press the radial shaft seal and the
rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan
bolt (5) as specified and remove the special tool.
Installation Notice
Tightening Torque(Bolt 1,5) 9 - 11 Nm
Seal Assembler 601 589 03 43 00

BELT PULLEY AND VIBRATION DAMPER

Preceding Work : Removal of cooling fan and viscous clutch
Removal of fan shroud
Removal of drive belt
1 Center Bolt (M18 x 50) ...... 1st step 200- 220 Nm 4 Vibration Damper Assembly
2nd step 90°+10° 5 Woodruff Key
2 Vibration Damper Disk 6 Bolt (M6 x 12, 4 pieces) ......................... 9-11 Nm
3 Bolt (M6 x 20, 6 pieces) ..................... 7.7-9.5 Nm 7 Cooling Fan Pulley
Components
1 Center Bolt (M18 x 50)

2 Center Bolt Washer
3 Vibration Damper and Pulley Assembly
4 Key
5 Crankshaft Front Seal
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)
Service Data Standard

Permissble Deviation of The Vibration Damper Radial Runout 0.6 mm
Axial Runout 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 65 09 00 Socket Wrench Insert
602 589 00 40 00 Engine Lock

1. Adjust the piston of number 1 cylinder to the TDC.
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
1st step 200 - 220 Nm
Tightening Torque
2nd step 90° +10°
Engine Lock 602 589 00 40 00
4. Remove the vibration damper assembly using the puller.

reverse order.
Notice
If possible, don’t separate the vibration damper and the
pulley.
CRANKSHAFT FRONT RADIAL SEAL

Preceding Work : Removal of belt pulley and vibration damper

................................ 1st step 200-220 Nm
2nd step 90° +10°
3 Sleeve (Special Tool)
5 Key
Tools Required
601 589 03 14 00 Sleeve
Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal mounting
hole and the crankshaft.
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
1st step 200 - 220Nm
Tightening Torque
2nd step 90° + 10°
5. Remove the sleeve and install the belt pulley and the
vibration damper.
6. Check for leaks while operating the engine.
CRANKSHAFT REAR RADIAL SEAL

Preceding Work : Removal of flywheel or drive plate
1 Special Tool 3 Crankshaft Rear Seal

2 Special Tool
Tools Required
601 589 03 43 00 Sleeve
Replacement Proceudre
Notice
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
Notice
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.
CRANKSHAFT
Preceding Work : Removal of engine assembly
Removal of timing gear case cover
Removal of cylinder head
Removal of oil pump
Removal of oil shield
1 12-sided Stretch Bolt ........ 55 Nm x 90°, Iubricate 4 Lower Thrust Bearing

2 Crank Shaft Bearing Cap 5 Crank Shaft
3 Crank Shaft Low Main Bearing
Arrangement of the Thrust Bearing and the Main Bearing
1 Upper Main Bearing A Crankcase Side

2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side)
3 Crankshaft C Axial Fit Bearing (Number 5 Bearing Point)
4 Lower Main Bearing D Radial Bearing
5 Lower Thrust Bearing
1 - 12 Weight Balance/Color Marking Point

j1 - j7 Journal Main Bearing #1 - #7
l Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6 , 8

,10 ,12 and it indicates the diameter of crankshaft journal
by color as below.
Color Dot Marking Crankshaft Journal Diameter (mm)

Blue 57.960 - 57.965
Yellow 57.955 - 57.960
Red 57.950 - 57.955
White 57.945 - 57.950
Violet 57.940 - 57.945
Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating surface to
oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing according
to the punching mark when repaired.
Punching Mark Bearing Color Selected

· Blue
·· Yellow
··· Red
2. Crankshaft Bearing Cap Side

Select the crankshaft main bearing according to the marking
letter on the crankshaft main journal when repaired.
Marking Letter Bearing Color Selected
B Blue
Y Yellow
R Red
W White
V Violet
Service Data Unit : mm

Crankshaft Crankshaft Crankshaft Connecting Rod Connecting
Crankshaft Standard Bearing Jour- Bearing Journal Width Bearing Journal Rod Bearing
and Repair Size nal Diameter Diameter at fit bearing Diameter Jourmal Width
Standard size 57.950-57.965 58 24.50-24.533 47.94-47.96 27.958-28.042
1st repair size 57.700-57.715 47.75
2nd repair size 57.450-57.465 - 47.50 -
3rd repair size 57.200-57.215 47.25
4th repair size 56.950-56.965 47.00
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap.
Installation Notice
Tightening Torque 40 Nm + 90°
l Make sure that the upper and lower bearing shells do

not change each other.
l Coat the bearing shell with engine oil.
l Install the bearing cap according to the consecutive
number.
2. Unscrew the crankshaft bearing cap bolts and separate the

upper and lower bearing shells and thrust washers.
Installation Notice
l Remove the bearing cap from front (pulley side) to rear.

not change each other and coat with engine oil.
l The oil grooves (arrows) in the thrust washers must face
outward and insert the thrust bearing into the bearing
cap.
l There are five kinds of thrust washers by thickness. Select
the proper washer when repaired. Part No. : 601 030 00 62 2.15 mm
Part No. : 601 030 01 62 2.20 mm
3. Remove the crankshaft. Part No. : 601 030 02 62 2.25 mm
4. Installation should follow the removal procedure in the Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
reverse order.
5. After completion of the installation, check for the rotating
condition of the crankshaft.
Installation Notice
l Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed,
the projected part (arrow) locates in the left side (intake
manifold side).
l Assemble so that the projected part of the cap and
crankcase face the same direction.
Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated

on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft

bearing.
Notice
l Measure at 2 points (1, 2).
l Measure ‘A’,‘B’and ‘C’ as shown. If average value of ‘B’
and ‘C’is less than value ‘A’, then the average value of
‘B’ and ‘C’ is actual average value. If average value of
‘B’ and ‘C’ is more than value ‘A’is actual average value.
4. Measure and record the diameter of the crankshaft bearing

journal.
Notice
l Record the mean value when measured at 3 points (A,
B, C).
l Measure the inner diameter of bearing and the diameter
of journal and if it is out of the standard data, replace
the bearing shell.
Service Data Standard (Crankshaft Main Bearing Gap)
Item Measuring Position Gap (mm)
Main Bearing Journal Static condition :0.015 - 0.039
( NO. 1, 5, 7) Radial Dynamic condition: 0.031 - 0.051
(Consider the expansion 0.011 - 0.016)
Axial 0.010 - 0.254
Main Bearing Journal Static condition :0.011 - 0.039
( NO. 3, 4, 6) Radial Dynamic condition: 0.031 - 0.051
(Consider the expansion 0.015 - 0.022)
Axial 0.010 - 0.254
(Connecting Rod Bearing Gap)

Connecting Rod Bearing Radial 0.030 - 0.050
FLYWHEEL / DRIVEN PLATE

Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) 3 Driven Plate (A/T)

............................................... 1st step 45+5 Nm 4 Dowel Pin
2nd step +90° +10°
2 Plate
Service Data Standard (Stretch Bolt)

Nominal Size D - M x 1.5
Stretch Side Diameter d When New 8.5 - 0.2 mm
Min. Diameter 8.0 mm
Bolt Length L When New 21.8 - 22.2 mm
Tightening Torque 1st step 50 Nm, 2nd step 90°
1. Unscrew the stretch bolt.
Installation Notice
1st step 45+5 Nm
Tightening Torque
2nd step 90° + 10°
l Replace the bolt when the stretch side diameter (d) of

the flywheel mounting bolt is less than 8.0mm.
l For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles, or

the driven plate (3), and plate (2) for Auto. transmission
vehicle.
reverse order.
Sectional View
1 Oil Pan
2 Cover
4 Flywheel MTG Bolt
5 Crankshaft
6 Dowel Pin
7 Plate
8 TGCC
9 Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear
CAMSHAFT ADJUSTER
1 Bolt (M6 x 16, 3 pieces) ........................ 9-11 Nm 13 Camshaft Sprocket and Position Indicator (b)
2 Electromagnetic Actuator (2 Pin Connector) 14 Adjuster piston
3 Bolt ........................................................... 35 Nm 15 Flange bolt (M7 x 13, 3 pieces)
4 Armature .............................................. 1st step 18-22 Nm
5 Roll Pin 2nd step 90° ± 5°
6 Nut (M20 x 1.5) .................................... 60-70 Nm 16 Flange Shaft
7 Front Cover 17 Compression Spring
8 Seal 18 Control Piston
9 Camshaft Position Sensor 19 Circlip
10 Bolt (M6 x 16, 2 pieces) ......................... 9-11 Nm 20 Oil Gallery
11 Seal 21 Pin
12 Seal Cover 22 Intake Camshaft
1. Turn the crankshaft to the direction of engine rotation and
position the no.1 cylinder piston at TDC which the camshaft
is positioned at OT.
2. Remove the cylinder head front cover.

3. Paint the alignment marks (arrows) on the intake and
exhaust camshaft sprocket and the timing chain.
4. Unscrew the bolt (3) from the armature (4) and remove the
armature.
Installation Notice
5. Unscrew the nut (6) and remove the ring and seal cover
(11).
Installation Notice
3 Bolt 12 Camshaft Sprocket

4 Amarture 17 Control Piston
6 Nut (M20 x 1.5) 21 Intake Camshaft
11 Seal Cover
6. Unscrew the sprocket bolt from the exhaust camshaft and
remove the sprocket.
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
The sprocket bolt is designed to be used only once, so

always replace with new one.
7. Remove the camshaft sprocket (13) and adjust piston (14),
and remove the flange shaft (16) from the intake camshaft
(22) after removing the bolt (15).
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
reverse order.
9. Adjust the camshaft timing.
CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
Notice
The sprocket bolts are designed to be used only once, so
C. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
Exhaust Camshaft Sprocket Bolt

1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
Notice
E. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft
CAMSHAFT
Preceding Work : Removal of cylinder head cover, removal of coolant connection fitting
1 Chain Tensioner Assembly .................. 72-88 Nm 5 Intake Camshaft Sprocket

2 Exhaust Camshaft Sprocket 6 Chain
3 Upper Guide Rail 7 Wrench (Special Tool)
4 Cylinder Head Front Cover
Tools Required
104 589 01 01 00 Spanner
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
3. Remove the chain tensioner.
4. Remove the cylinder head front cover and the upper guide
rail.
5. Put the alignment marks (arrows) on the camshaft sprocket

(2, 5) and the timing chain (6).
6. Unscrew the exhaust camshaft sprocket bolt and remove

the sprocket.
7. Separate the chain from the intake camshaft sprocket and
put the chain not to be dropped into timing case.
8. Unscrew the intake side bolts (8, 11, 13, 14) and the exhaust
side bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and
exhaust side camshaft bearing cap bolts.
Notice
Number the camshaft bearing cap bolts when removing
them, so that they don’t get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Install the exhaust camshaft bearing caps (2, 3, 5) and the
intake camshaft bearing caps (9, 10, 12). Tighten the bolts
with specified torque and install the remaining bearing caps.
Notice
Install the bearing caps according to the numbers on the

bearing caps.
3. Turn the camshaft using the wrench (special tool) so that

the intake camshaft adjustment hole lines up with the cylinder
head upper side (3 o’clock direction at the intake, 9 o’clock
direction at the exhaust).
Notice
Turn the crankshaft and adjust it to OT so that No. 1 cylinder’s
piston would be at TDC.
4. Turn the intake camshaft adjuster to the direction of camshaft
rotation by hard until it stops and then install the chain.
Notice
l Make sure that the camshaft sprocket and timing chain
are aligned with marks.
l Intake camshaft adjuster should be in retarded position.
5. Install the chain on the exhaust sprocket and tighten the

sprocket bolts.
Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
l Make sure that the camshaft sprocket and timing chain

are aligned with marks.
l Replace the sprocket bolt with new one.
6. Install the chain tensioner and tighten it as specified.

Notice
(1) 40 Nm
Tightening Torque
(2) 72 - 88 Nm
7. Rotate the crankshaft 2 revolutions and check followings:

- TDC of no. 1 cylinder : OT
- Alignment between camshaft adjustment hole and
cylinder head surface.
- Alignments between timing chain and sprocket marks.
Notice
l Turn the crankshaft in the direction of engine rotation.
l Read just if not aligned.
8. Install the upper guide rail and cylinder head front cover.
9. Install the alternator.
CAMSHAFT TIMING POSITION

1 Chain Tensioner Assembly 4 Cylinder Head Front Cover

2 Exhaust Camshaft Sprocket 5 Wrench (Special Tool)
3 Upper Guide Rail 6 Adjustment Hole Fitting Pin (f 4.0 mm)
Tools Required
104 589 01 01 00 Spanner
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning
the crankshaft.
Notice
When the OT mark on vibration damper is aligned with timing
gear case cover, the intake and exhaust cam of cylinder
will make the slope to the center and will face up. In this
way, the adjustment hole of the intake and exhaust camshaft
will match in line with the cylinder head upper end, at 3
o’clock, and 9 o’clock direction each other.
2. Check the timing as below procedure;
- Check if the camshaft adjustment hole is positioned to 3
o’clock direction at the intake side and to 9 o’clock
direction at the exhaust side, respectively and align with
the cylinder head mating surface.
- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30° .
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with the
cylinder head upper surface.
l Intake Side : 3 o’clock direction
l Exhaust Side : 9 o’clock direction
5. Secure the intake and exhaust camshaft.
6. Position the piston of No.1 cylinder at TDC (OT) by turning
the crankshaft.
7. Turn the camshaft adjuster of the intake camshaft to the
left as much as possible (cam adjuster ‘retarded’ position).
8. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in gear case
cover.
9. Install the chain to the exhaust camshaft sprocket and
install it to the camshaft.
Installation Notice (Sprocket Bolt)
1st step 18 - 22 Nm
Tightening Torque
2nd step 90° ± 5°
replace with new one.
10. Install the chain tensioner.
Installation Notice
Tightening Screw Plug 40 Nm

Torque Tensioner Assembly 72 - 88 Nm
11. Check the camshaft timing.

VALVE SPRING
Preceding Work : Removal of camshaft
Removal of spark plug
1 Valve Tappet Assembly 7 Connecting Hose

2 Valve Cotter 8 Thrust Piece
3 Upper Retainer 9 Slide
4 Valve Spring .......... Check, Replace if necessary 10 Adjust Bolt
5 Valve Stem Seal 11 Lever Pusher
6 Lower Retainer 12 Supporting Bar
Tools Required
111 589 01 59 00 Supporting Bar
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece
116 589 06 63 00 Magnetic Finger

1. Place the supporting bar (12) and the slide (9) at the
camshaft bearing cap (Nos 1 & 7/8&14) and tighten them
with the bearing cap bolt.
Installation Notice
Supporting Bar 111 589 01 59 00
2. Turn the crankshaft to position the each cylinder piston at

TDC.
Mark on The Vibration Damper Cylinder
OT 1, 6
120° 2, 5
240° 3, 4
Notice
l Remove the valve spring only at TDC.
l Always rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and for
smooth rotation.
3. Remove the valve tappet (1) using the magnetic finger.
4. Install the leakage tester connecting hose to the spark plug
hole.
5. Install the engine lock to the ring gear to prevent the
crankshaft from rotating.
6. Blow up with compressed air.
8. Install the lever pusher (11) and the thrust piece (8) to the
slide (9).
Lever Pusher 111 589 18 61 00
9. Mount the thrust piece (8) vertically to the valve spring

retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular
to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
13. Remove the valve cotter (2) using either the pincette (13)
or magnetic finger.
Magnetic Finger 116 589 06 63 00
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
Notice
Check the retainer for damages and replace with a new
one if necessary.
reverse order.
Test (Upper and Lower Valve Tappet and Valve
Cotter)
l Upper Valve Spring Retainer
(d) 8.5
Size (mm)
(D) 12.3
l Lower Valve Spring Retainer
Thickness (mm) (a) 0.8 - 1.0
l Valve Cotter
(B) 9.0
Size (mm)
(H) 9.2 - 9.8
VALVE STEM SEAL

Preceding Work : Removal of valve spring
1 Drift (Special Tool)

2 Valve Stem Seal
3 Protective Sleeve
Tools Required
104 589 00 37 00 Pliers
119 589 00 43 00 Drift
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
Pliers 104 589 00 37 00
2. Coat the valve stem seal with oil and assemble it with the
protective sleeve.
3. Insert the valve stem seal by pressing it with the drift.
Drift 119 589 00 43 00

CHAIN TENSIONER
1 Screw Plug ................................................ 40 Nm 5 Snap Ring

2 Seal 6 Thrust Pin
3 Filler Pin 7 Chain Tensioner Housing ..................... 72-88 Nm
4 Compression Spring 8 Seal
Removal Procedure
1. Position the No.1 cylinder to TDC (OT).
Notice
Remove the oil filler cap at adjustment position, and check
whether the intake camshaft cam’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.
If the chain tensioner is tightened again without completely
reducing its tension, then the detent spring doesn’t return
to the original position and the tension gets excedded.
4. Carefully unscrew the screw plug (1), and remove the seal
(2).
Notice
l For the removal of screw plug, be careful that it can be
jumped out due to the force of compression spring.
l Remove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring (4),
snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).
1. Connect the thrust pin (6) and the snap ring (5) to the chain
tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust pin far
enough so that it doesn’t protrude at the chain tensioner
housing.
2. Install the chain tensioner housing (7), thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
3. Insert the compression spring (4) with the filler pin (3) into
chain tensioner housing.
4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
5. Check for leaks by operating the engine.
Sectional View
1 Screw Plug 13 Chain Tensioner Housing

2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail
7 Compression Spring 19 Cylinder Head Gasket
8 Snap Ring 20 Timing Chain
9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface)
10 Ball (Nonreturn Valve) A Oil Supply Hole
11 Compression Spring B Chain Tensioner Oil Storage Hole
12 Thrust Piece
TIMING CHAIN
1 Pin 5 Link
2 New Timing Chain 6 Center Plate
3 Timing Chain (Used) 7 Outer Plate
4 Wedge
Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
1. Position the No.1 cylinder to TDC (OT).
2. Insert the f 4mm pin to the intake and exhaust camshaft

flange not to rotate camshaft.
4. Mount the wedges to both sides of the camshaft sprocket

as shown in the figure.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket with
the grinder.
6. Remove the outer plate (7) with the screw driver and
remove the link (5).
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the
link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.
12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool.
15. Replace the thrust piece (b) as shown in the figure.
16. Install the assembly tool to the link pin and tighten the
spindle (c).
17. Rivet the link pin.
Check the condition and it again if necessary.
Installation Notice
Tightening Screw Plug 40 Nm

Torque Tensioner Assembly 72 - 88 Nm
19. Check the camshaft timing position.

TENSIONING RAIL
Preceding Work : Removal of timing gear case cover
1 Tensioning Rail
2 Plastic Guide
3 Tensioning Rail Pin
4 Guide Rail

1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
3. Remove the tensioning rail (1) from the tensioning rail pin
(3).
Notice
l Replace the plastic guide (2) if it is damaged.
l For installation, exactly align the plastic guide (2) with
the tensioning rail (1).
reverse order.
CYLINDER HEAD GUIDE RAIL

1 Chain Tensioner
2 Upper Guide Rail
3 Upper Guide Rail Pin
4 Wrench (Special Tool)
Tools Required
104 589 01 01 00 Spanner

1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating direction
using the wrench (4) and loosen the timing chain at upper
guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of
rotation using the wrench (4, special tool : 104 589 01 01
00).
5. Check for damages at the upper sliding rail and replace it if
necessary. Install the upper guide rail pin.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
Tensioner Assembly 72 - 88 Nm
CRANKCASE GUIDE RAIL

1 Guide Rail
2 Plastic Guide
3 Guide Rail Pin
4 Tensioning Rail

1. Put the assembly mark at the camshaft sprocket and the
timing chain with the paint (arrow).
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
l Replace the plastic guide (2) if damaged.
l Connect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
reverse order.
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil pan
Removal of tensioning rail
Removal of crank case guide rail
1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer .......... 29-35 Nm
2 Oil Pump Chain Bushing 7 Oil Pump Sprocket
3 Oil Pump Chain Spring 8 Oil Pump
4 Crankshaft Sprocket 9 Oil Pump Roller Chain
5 Key 10 Timing Chain
Tools Required
615 589 01 33 00 Puller

1. Put the assembly mark at the crankshaft sprocket (4) and
the timing chain (10) with the paint (arrow).
Installation Notice
Align the assembly marks on cranshaft sprocket and timing
chain. Also, align the assembly marks on camshaft sprocket
and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7)
from the oil pump.
Installation Notice
3. Remove the oil pump roller chain (9).

4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the puller (04,
special tool).
Notice
l Make sure not to lose the crankshaft pulley key(5) when
removing.
l Install the crankshaft sprocket(4) after warming it up.
reverse order.
Puller (04) 615 589 01 33 00

PISTON
Preceding Work : Removal of engine
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1 Connecting Rod Bearing Cap 4 Piston

2 Connecting Rod 5 Snap Ring
3 Connecting Rod Bolt (M9 x 52, 12 pieces) 6 Piston Pin
.................................................... 1st step 40 Nm
2nd step 90° + 5°
Tools Required
001 589 72 21 00 Torqued Wrench
000 589 04 14 00 Clamping Strap
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.
Notice
Make sure that the bearing cap and shell are not changed
each other.
3. Remove the snap ring (5) and pull out the piston pin (6).
Notice
Remove the snap ring using a clean cloth as shown in the
right picture so that the piston, piston ring, and the snap
ring don’t get damaged.
1. Check the piston ring gap and apply the engine oil to the
piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in
the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and the piston and coat them
with engine oil.
4. Install the piston ring using the tensioning strap(000 589
04 14 00).
5. Install the piston so that the arrow on the piston head faces
to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark
(// or a number), tighten the bolts.
Installation Notice
1st step 35 - 45 Nm
Tightening Torque
2nd step 90° + 5°
Apply the engine oil to the bearing cap upper and lower
bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating
it.
CONNECTING ROD
Preceding Work : Removal of piston
1 Connecting Rod Bushing

2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt
(M9 x 52, 12 m pieces) .. 1st step 40+5 Nm
2nd step 90°+10°
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]

Distance (L) from The Connecting Rod Bearing Bore Center to The Bushing Bore Center 145 ± 0.05 mm
Width of The Connecting Rod (B) at Bearing Bore 21.940 - 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore 21.940 - 22.000 mm
Basic Bore at The Bearing Shell (D1) 51.600 - 51.614 mm
Basic Bore at The Bushing (d1) 24.500 - 24.571 mm
Bushing Inner Diameter (d) 22.007 - 22.013 mm
Clearance Between The Piston Pin and The Bushing 0.007 - 0.018 mm
Peak-to-valley Height of Connecting Rod Bushing on Inside 0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore 0.15 mm
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting 0.07 mm
Rod Bushing Core
Permissible Deviation of Connecting Rod Bearing Bore from Concentricity 0.01 mm
Permissible Difference of Each Connecting Rod in Weight 0.4 g
Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614mm, replace
the bearing or check the connecting rod.
2. Check connecting rod bolts.

Length When New (L) 51.7 - 52 mm
Max. Length (L) 52.9 mm
Tightening Torque 1st step 40 + 5 Nm
2nd step 90°+10°
Notice
If the length exceeds max. length, replace it.
3. Check the assembly mark(indication//or number:arrow) of

the connecting rods and the bearing cap when installing.
Notice
l Make sure it doesn’t exceed over 4g with other
connecting rods when replacing the connecting rods.
l Check if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing.
PISTON RING
1 Piston Compression Ring

2 Piston Compression Ring
3 Piston Oil Ring
4 -
5 Coil Spring and Control Ring
6 Hook Spring
Tools Required
1. Measure the piston ring’s gap.
End Gap of The Groove 1 0.20 - 0.40 mm
Piston Ring Groove 2 0.20 - 0.40 mm
Groove 3 0.20 - 0.45 mm
Gap Between Groove 1 0.015 - 0.050 mm
The Piston and Groove 2 0.020 - 0.040 mm
The Piston Ring
Groove 3 0.010 - 0.045 mm
Notice
If out of specification, replace the piston ring.
2. Remove the piston ring with a pliers.
Clamping Strap 000 589 51 37 00
3. For installation, position the piston ring to be the ‘TOP’ mark

on the piston ring upward and arrange the piston ring ends
to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away from
the ring end.
ENGINE OIL SPECIFICATION
1 Drain Plug ................................................. 25 Nm 3 Engine Oil Filler Cap

2 Oil Filter 4 Dipstick Gauge
Specifications
Application Descrition
Capacity Min : 6.7L, Max : 8.2L
Quality l API SH or above grade
l ACEA : A2 or A3
l Approved oil by MB Sheet 229.1
Viscosity l Approved oil by MB Sheet 224.1
Replacemant l Initial at 1000-1500km, Replace every 15000km
OIL PAN
1 Gasket ................................................... Replace 5 Bolt (M6 x 85) ............................................ 10 Nm

2 Bolt (M6 x 22, 6 pieces) ............................ 10 Nm 6 Bolt (M8 x 40) ............................................ 25 Nm
3 Drain Plug (M6 x 20) ................................. 25 Nm 7 Bolt (M10) ................................................. 40 Nm
4 Bolt (M6 x 20, 22 pieces) .......................... 10 Nm 8 Oil Pan

1. Remove the drain plug and drain the oil completely.
2. Disconnect the electric connector from oil level switch.
3. Unscrew the bolts (10) for oil level switch and check the O-
ring (11) for wear or damage. And replace it if necessary.
4. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
5. Clean the inside of oil pan and sealing surface, then apply
the sealant.
7. Install the oil pan with gasket, and tighten each bolt in M8 X 40, 4 pieces
specified torque. M6 X 85, 3 pieces
8. Check for oil leaks while running the engine. M6 X 35, 3 pieces
the rest M6 X 20, 28 pieces
Oil Circulation
1 Oil Pump 19 Oil Supply (To Intake Camshaft)

2 Oil Gallery (to oil filter) 20 Oil Supply (To Exhaust Camshaft Bearing)
3 Oil Filter 21 Oil Supply (To Intake Camshaft Bearing)
4 Oil Pressure Switch 22 Oil Gallery (Oil Supply to Exhaust Valve Tappet)
5 Main Oil Gallery 23 Oil Gallery (Oil Supply to Exhaust Valve Tappet)
6 Cylinder Head Closing Cover 24 Camshaft Closing Cover
7 Oil Gallery (At Chain Tensioner) 25 Ball (f 8 mm)
8 Oil Non-return Valve 26 Screw Plug
9 Chain Tensioner 27 Camshaft Adjuster
10 Vent (Chain Tensioner) 28 Front Closing Cover (Intake Camshaft)
11 Front Closing Cover (f 17 mm) 29 Front Treaded Bushing (Exhaust Camshaft)
12 Oil Gallery (Perpendicular to The Shaft) 30 Valve tappet
13 Ball (f 6 mm)
14 Oil Spray Nozzle (Timing Chain) a Oil Gallery (From Oil Pump to Oil Filter)
15 Oil Gallery (At Cylinder Head) b Main Oil Gallery
16 Ball (f 15mm) c Oil Return Line (Oil Returns to the Oil Pan when
17 Oil Restriction Inner (f 4mm) Replacing the Filter Element)
18 Oil Supply (To Exhaust Camshaft)
ENGINE OIL AND OIL FILTER ELEMENT

Tools Required
103 589 02 09 00 Oil Filter Socket Wrench
1. Install the socket wrench”7” (special tool : 103 589 02 09
00) on the oil filter cover (2).
Notice
Make the screw cover removable by tightening the bolt at
the side of the socket wrench (special tool).
2. Install the wrench to the upper bolt in the socket wrench
and remove the oil cover by turning it.
3. Remove the oil filter element.
Notice
Work with a cloth under the vehicle when removing the oil
filter element to not drain the oil.
4. Remove the drain plug (arrow) and drain the engine oil.
Notice
Leave the oil filler cap open to ease the engine oil discharge.
5. Tighten the engine oil drain plug after cleaning it.
Installation Notice
Replace the seal washer with new one.

6. Replace the O-ring(5) in the oil filter cover with new one.
Notice
Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover (2). Install the socket
wrench “7” (special tool : 103 589 02 09 00), and then
completely tighten it.
Installation Notice
2 Oil Filter Cover

5 O-ring
6 Oil Filter Element
7 Special Tool (Socket Wrench)
9. Fill up engine oil through the engine oil filler opening (3).
10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.
3 Oil Filler Cap

4 Dipstick Gauge
OIL FILTER
Preceding Work : Removal of starter motor
Removal of upper intake manifold
1 Coolant Line 5 Bolt ........................................................... 23 Nm

2 O-ring .................................................... Replace 6 Oil Filter
3 Clip 7 Gasket ................................................... Replace
4 Hose
1. Drain the coolant from the crank case.
2. Remove the each coolant line and hose.
3. Remove the oil filter bolt and then remove the oil filter.
Installation Notice
Notice
Replace the oil filter gasket.

reverse order.
5. Check engine oil level.
6. Run the engine at idle and check the engine for leaks.
OIL PUMP
1 Bolt (M8 x 20, 1 piece) ......................... 29-35 Nm 4 Spring Pin

2 Sprocket (Oil Pump Drive) 5 Oil Pump
3 Bolt (M8 x 35, 3 pieces) ................. 22.5-27.5 Nm
1. Remove the bolt (1) from the oil pump drive sprocket
(2) and separate the gear and the oil pump drive chain.
Installation Notice
2. Unscrew the oil pump mounting bolts (3).

Installation Notice

Tighten the baffle plate and the oil pump with the two bolts
in right side first, and then tighten the other bolt.
3. Unscrew the bolt (9) from the oil strainer bracket.

Installation Notice
4. Remove the oil pump and oil strainer assembly.

5. Replace the strainer in oil pump if necessary.
reverse order.
OIL PRESSURE RELIEF VALVE

1 Screw Plug ................................................ 50 Nm 3 Guide Pin

2 Compression Spring 4 Piston

1. Remove the screw plug (1).
Installation Notice
2. Remove the spring (2), guide pin (3) and the piston (4).
reverse order.
Notice
Don’t use the seal for the screw plug.
OIL NON-RETURN VALVE

1 Oil Non-return Valve
Functions
The non-return valve prevents the oil in the chain tensioner
from drying up. In other words, it stops oil-returning in order to
prevent the oil in the chain tensioner from getting dry. As a
result, the chain tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.
OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge 3 O-ring

2 Oil Dipstick Guide Tube 4 Bolt (M6 x 12, 1 piece) ........................... 9-11 Nm

1. Pull out the oil dipstick level gauge (1).
2. Remove the bolt (4) in the upper intake manifold and remove
the oil dipstick guide tube.
Installation Notice
3. Install new O-ring to the dipstick guide tube.

reverse order.
5. Check for leaks by starting the engine.
UNIT REPAIR
OIL GALLERY IN CRANKCASE
Preceding Work : Removal of crankshaft, removal of oil spray nozzle
1 Plug 3 Round Bar ................................... f 11 x 750 mm

2 Steel Ball
Cleaning Procedure
1. Remove the plug (1) with a screwdriver.
2. Using a round bar (3) and hammer, remove the steel ball
(2).
3. Using the compressed air, blow into the oil galleries and
clean it off.
1 Plug ....................................................... Replace 3 Screw Plug

2 Main Oil Gallery
Tools Required
102 589 12 15 00 Drift
Sealing Procedure
1. Enlarge the end of main oil gallery (4) to be diameter of
16mm, depth of 15mm.
2. Using an M16 x 1.5 thread (tap), make the thread at the
end of main oil gallery (4).
3. Throughly clean the oil gallery with compressed air and
tighten the screw plug (M16 x 1.5) after applying sealing
bond on it.
4. Apply Loctite 270 on new plug and tighten to the hole until
the drift is stopped after inserting new plug into the drift.
OIL GALLERY IN CYLINDER HEAD

Preceding Work : Removal of cylinder head
Removal of camshaft
Removal of tappet
1 Screw Plug ................................................ 15 Nm 3 Steel Ball (f 8mm)

2 Seal
Cleaning Procedure
1. Remove the screw plug (1) and the seal (2).
Installation Notice
Replace the seal with new one.
2. Clean the oil gallery using the compressed air.

Sealing Procedure
1. Remove the screw plug (1) and the seal.
Installation Notice
2. Remove the steel ball from the oil gallery (4), (5), (6) and
(7) using the round bar (12, f 6 x 700 mm).
3. Remove the plug (8) using the screw driver.
4. Enlarge the oil gallery at the rear of the cylinder head to be

diameter 9mm, depth 8mm.
5. Tap in the steel ball (3) from the side to the oil gallery using
the punch (13).
6. Pull out the steel ball (3) using the round bar (12).
7. Enlarge the oil gallery to be diameter 9mm, depth 8mm.
8. Make a screw hole at the oil gallery using M10 x 1 thread.
9. All the oil gallery should be cleaned with the compressed
air.
10. Apply the Loctite 270 to new plug and press in using a
suitable drift (arrow).
11. Tighten the screw plug with the seal (arrow).
Screw Plug (Part No. 000 908 01 00 02)

Seal (Part No. 007 603 01 01 03)
CORE PLUGS IN CRANKCASE

Preceding Work : Draining of the coolant
1 Core Plug ............................................... Replace

Tools Required
102 589 00 15 00 Drift
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes out
using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.

Notice
Wait for about 45minutes before filling the coolant so that
the Loctite 240 hardens.
6. Warm up the engine and check the coolant for leaks.

CYLINDER BORE
Group Code Letter and Cylinder Bore Size

Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm)
A A or X f 89.900 - f 90.906
X A, X or B f 89.906 - f 89.912
B X or B f 89.912 - f 89.918
X+5 X+5 f 89.950 - f 89.968
X + 10 X + 10 f 90.000 - f 90.018
Repair Size
Type Group Code Letter1) Cylinder Bore Size (mm)
Standard Size f 89.9 A f 89.900 - f 90.906
X f 89.906 - f 89.912
B f 89.912 - f 89.918
1st Repair Size A f 90.150 - f 90.156
(Standard Size + 0.25) X f 89.156 - f 90.162
B f 90.162 - f 90.168
2nd Repair Size A f 90.400 - f 90.406
B f 90.412 - f 90.418
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
Wear Limit in Longitudinal and Transverse Direction 0.1 mm
Permissible Deviation of Cylinder Out-of-round When new 0.007 mm
Wear limit 0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm
Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm
Chamfer Angle 60°
Honing Angle 50° ± 10°
Measurement of Cylinder Bore

1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size in
axial and transverse direction at three points (1,2,3).
1,2,3. Measuring Points

A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle
CRANKCASE MATING SURFACE

Height of The Crankcase “H” (When new) 282.25 - 282.35mm
Minimum Height After Milling 281.95mm
Flatness Crankcase Upper Mating Surface 0.03mm
Crankcase Lower Mating Surface 0.04mm
Permissible Deviation of Parallelism of The Axial Direction 0.1mm
Upper to Lower Mating Surface Transverse Direction 0.05mm
Peak-to-valley Height Crankcase Upper Mating Surface 0.005 - 0.020mm
Chamfering Procedure
1. Chamfer angle : 60°
2. Polish the lower chamfered area evenly with a grinder after

finishing the chamfering with a suitable tool (e.g., hand milling
cutter).
CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of valves

Overall Height of Cylinder Head 135.9 - 136.0 mm
Minimum Height After Machining 135.5 mm
Flatness Axial Direction 0.08 mm
Transverse Direction 0.0 mm
Distance ‘T’ Standard Size Intake 24.21 - 24.75 mm
(Between Camshaft Bearing Exhaust 22.21 - 22.75 mm
and Valve Stem) Repair Size Intake 23.96 - 24.51 mm
Exhaust 21.96 - 22.51 mm
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.
Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard).
Universal Tool
Sceledum, Type RTY
Surface Grinding Machine Roaro
Schio/Italy
SECTION 1B2
M161 ENGINE MECHANICAL

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B2-2 Camshaft Sprocket Bolt . . . . . . . . . . . . . . . 1B2-65
Fastener Tightening Specifications . . . . . . . . 1B2-2 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-66
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B2-4 Camshaft Timing Position . . . . . . . . . . . . . . 1B2-69
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B2-4 Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . 1B2-72
Maintenance and Repair . . . . . . . . . . . . . . 1B2-9 Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 1B2-76
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1B2-9 Chain Tensioner . . . . . . . . . . . . . . . . . . . . . 1B2-77
Engine Assembly . . . . . . . . . . . . . . . . . . . . . 1B2-9 Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . 1B2-80
Crankcase Ventilation System . . . . . . . . . . 1B2-17 Tensioning Rail . . . . . . . . . . . . . . . . . . . . . . 1B2-85
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-21 Cylinder Head Guide Rail . . . . . . . . . . . . . . 1B2-86
Power Steering Pump and A/C Bracket . . . 1B2-22 Crankcase Guide Rail . . . . . . . . . . . . . . . . . 1B2-87
Hydraulic Engine Mounting Insulator . . . . . . 1B2-25 Crankshaft Sprocket . . . . . . . . . . . . . . . . . . 1B2-88
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-28 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-90
Tensioning Deivce . . . . . . . . . . . . . . . . . . . . 1B2-30 Connecting Rod . . . . . . . . . . . . . . . . . . . . . 1B2-93
Tensioning Device Shock Absorber . . . . . . 1B2-31 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-95
Poly V-Belt Inspection . . . . . . . . . . . . . . . . . 1B2-32 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-97
Cylinder Head Cover . . . . . . . . . . . . . . . . . 1B2-35 Engine Oil and Oil Filter Element . . . . . . . . 1B2-99
Cylinder Head Front Cover . . . . . . . . . . . . . 1B2-37 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-101
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B2-39 Oil Pressure Relief Valve . . . . . . . . . . . . . 1B2-103
Timing Gear Case Cover . . . . . . . . . . . . . . 1B2-44 Oil Non-Return Valve . . . . . . . . . . . . . . . . 1B2-104
Crankshaft Sealing Rear Cover . . . . . . . . . 1B2-47 Oil Dipstick Guide Tube . . . . . . . . . . . . . . 1B2-105
Belt Pulley and Vibration Damper . . . . . . . . 1B2-49 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B2-106
Crankshaft Front Radial Seal . . . . . . . . . . . 1B2-52 Core Plugs in Crankcase . . . . . . . . . . . . . 1B2-106
Crankshaft Rear Radial Seal . . . . . . . . . . . 1B2-53 Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . 1B2-108
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B2-54 Crankcase Mating Surface . . . . . . . . . . . . 1B2-110
Flywheel/Driven Plate . . . . . . . . . . . . . . . . . 1B2-60 Cylinder Head Mating Surface . . . . . . . . . 1B2-112
Camshaft Adjuster . . . . . . . . . . . . . . . . . . . 1B2-62
SPECIFICATIONS
Application N·
·m
Power Steering Hydraulic Lines 35 - 40
A/C High Pressure and Liquid Hose 10 - 15
Radiator Support Menber Bolt 5 - 10
Fuel Supply and Return Hose to Fuel Distributor 21 - 25
Exhaust Manifold and Pipe 30
Propeller Shaft to Transmission 56 - 66
Alternator Carrier Bolt 22.5 - 27.5
Belt Pulley Bolt 41.5 - 49.5
Steering Pump Bolt 22.5 - 27.5
A/C Bracket Bolt 22.5 - 27.5
Intake Air Duct Bolt 9 - 11
Ignition Cable Cover Bolt 9 - 11
Cylinder Head Cover Bolt 9 - 11
Camshaft Adjuster Bolt 9 - 11
Cylinder Head Front Cover Bolt 22.5 - 27.5
Flange Bolt in Exhaust Camshaft Sprocket 10
+90°
Cylinder Head Bolt 55
+90°
+90°
Cooling Fan Bracket Bolt 22.5 - 27.5
Timing Gear Case Cover Bolt M8 22.5 - 27.5
M6 9 - 10
Crankshaft Rear Cover Bolt 9 - 10
Vibration Damper Center Bolt 200
+90°
Connecting Rod Bearing Cap Bolt 40
+90°
Flywheel Stretch Bolt 45
+90°
Amarture Bolt in Flywheel 35
Ring and Seal Cover Nut in Flywheel 9 - 11
Sprocket Bolt to Exhaust Camshaft 20
+90°
Camshaft Adjuster Flange Bolt 20
+90°
Intake Flange Shaft Bolt 20 / + 90°
Exhaust Camshaft Sprocket Bolt 20 / + 90°
Camshaft Bearing Cap Bolt 22.5 - 27.5
FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application N·
·m
Exhaust Camshaft Sproket Bolt 20 / + 90°
Chain Tensioner Screw Plug 40
Chain Tensioner Assembly 72 - 88
Exhaust Camshaft Sprocket to Camshaft 20 / + 90°
Oil Pump Sprocket Bolt 25 - 35
Tensioning Device Bolt 22.5 - 27.5
Water Pump Pulley 22.5 - 27.5
Upper Intake Manifold Bolt 22.5 - 27.5
Lower Intake Mainfold Bolt 22.5 - 27.5
Flange Bolt to Exhaust Mainfold 30
Exhaust Mainfold Nut to Stud Bolt 26 - 34
Rivet Nut in Exhuast Mainfold Hole 30
Pre-Silencer Bolt 8 - 10
Oil Drain Plug 25
Oil Filter Cover 25
Oil Filter Bolt 22.5 - 27.5
Oil Pump Drive Sprocket Bolt 29 - 35
Oil Pump Mounting Bolt 22.5 - 27.5
Oil Strainer Bracket Bolt 9 - 11
Oil Pressure Relief Valve Screw Plug 50
Oil Dipstick Guide tube Bolt 9 - 11
Oil Gallery Screw Plug 15
SPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 000 589 40 37 00

Torque Wrench Hose Clamp
112 589 00 72 00 000 589 72 21 00

Oil Extractor Torque Wrench
001 589 66 21 00 124 589 15 21 00

Torque Wrench Radiator Cap
Testing Unit
000 589 01 10 00 116 589 02 34 00

Box Wrench Insert Screw-Fixed Pin
104 589 01 01 00 111 589 01 59 00

Spanner Supporting Bar
111 589 18 61 00 111 589 25 63 00

Lever Pusher Thrust Piece
116 589 06 63 00 104 589 00 37 00

Magnetic Finger Pliers
119 589 00 43 00 000 589 58 43 00

Drift Chain Assembly
116 589 20 33 00 601 589 03 43 00

Sliding Hammer Sleeve
602 589 00 40 00 103 589 00 33 00

Engine Lock Puller
001 589 65 09 00 000 589 88 33 00

Socket Wrench Insert Puller
001 589 74 21 00 000 589 04 14 00

Torque Wrench Clamping Strap
103 589 01 63 00 615 589 01 33 00

Rivet Set Caulking Bolt
103 589 02 09 00 102 589 12 15 00

Oil Filter Drift
Socket Wrench
102 589 00 15 00 601 589 03 14 00

Drift Sleeve
000 589 51 37 00 001 589 72 21 00

Clamping Strap Torque Wrench
617 589 00 10 00 116 589 01 34 00

Wrench Socket Threaded Bolt
104 589 00 40 00 111 589 03 15 00

Holder Insert Pin

ON-VEHICLE SERVICE
ENGINE ASSEMBLY
Tools Required
000 589 40 37 00 Hose Clamp
112 589 00 72 00 Oil Extractor
2. Remove the hood.
3. Remove the under cover.
Installation Notice
4. Disconnect the coupling of HFM sensor and remove the air

cleaner cross pipe.
5. Remove the air cleaner cover. Remove the mounting bolts

and air cleaner housing and element assembly.
6. Loosen the radiator drain cock and drain the coolant.

Notice
Open the coolant reservoir cap.
7. Loosen the cylinder block drain plug and then drain the
coolant completely.
Installation Notice
Notice
Replace the seal before installation of the drain plug.
9. Disconnect the each hose from radiator.
10. Remove the upper mounting bolts of radiator and then

remove the radiator.
11. Remove the hydraulic pipe of power steering.
Notice
Completely drain the oil.
12. Discharge the refrigerant from A/C system, and disconnect

the discharge pipe and suction pipe from the compressor.
13. Remove the acceleration control cable and automatic

transmission pressure cable.
14. Remove the fuel feed and return line.

Notice
Before removing the fuel lines, release the pressure in the
fuel system.
Installation Notice
15. Remove the automatic transmission dipstick guide tube.
16. Disconnect the wire of alternator.
17. Disconnect the wire of starter motor and remove the starter
motor.
18. Disconnect the engine main harness ground.
19. Disconnect the engine ground wire.

20. Disconnect following sensors connector.
l HFM sensor.
l Coolant temperature sensor.
l 2 knock sensors.
l Camshaft and crankshaft sensors.
21. After removing the ignition coil cover, disconnect the ignition
coil connector.
22. Remove the harness cover and disconnect the 6 injection
valve connectors. Disconnect the main harness.
23. Separate the hose toward engine from canister purge

solenoid valve.
24. Remove the automatic transmission oil cooler line.

25. Separate the vacuum hose for brake booster.
26. Separate the other vacuum hoses.
27. Remove the propeller shaft from the front axle.

Installation Notice
28. By rotating the crankshaft from the front of engine, remove

the 6 torque converter mounting bolts from the engine
ring gear plate.
29. Remove the exhaust manifold and exhaust pipe.

Installation Notice
30. Remove the transmission mounting bolts and separate
the transmission from the engine.
Installation Notice
31. Remove the bolts for engine mounting bracket.

Installation Notice
32. Hook the chain to the bracket of engine and by using a

hoist or crane, carefully separate the engine assembly
from the vehicle.
reverse order.
CRANKCASE VENTILATION SYSTEM

1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling)

2 Cylinder Head Cover 12 Crank Chamber
3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe
Mid-Load) 14 Oil Pan
4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover
5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase
6 Throttle Valve 17 Chain Housing
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling)
8 Intake Manifold A Fresh Air
9 Vent Line (Mid-Load at Idling) C Blow-by Gas
10 Air Conditioner Bracket D Vent Connection
l The throttle valve(6) is closed or very partially opened, and
the vacuum pressure in intake manifold is high.
The blow-by gas and the fresh air that is additionally supplied
through the vent connection(D) in the crankcase in partial
load gets supplied to the combustion chamber from the crank
chamber(12) through the oil separation chamber(11), air-
conditioner bracket(10), vent line(9), and restrictor(7)
mounted to the cylinder head.
The circulated engine oil returns to the oil pan through the
oil return pipe(13) at the bottom of oil separation
chamber(11).
The fresh air gets supplied to the crank chamber(12) through
the HFM sensor(1), intake air duct(4), vent line(5), oil
separation chamber(3), chain housing(17), and the timing
gear case cover(15).
The additional supply of the fresh air is needed to prevent
from forming the residues of the engine oil.
Operation When Full-Load at Partial Load
1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling)

2 Cylinder Head Cover 12 Crank Chamber
3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe
Mid-Load) 14 Oil Pan
4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover
5 Vent Line (Full-Load or Over Mid-Load) 16 Crankcase
6 Throttle Valve 17 Chain Housing
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling)
8 Intake Manifold A Fresh Air
9 Vent Line (Mid-Load at Idling) C Blow-by Gas
10 Air Conditioner Bracket D Vent Connection
Operation When Full-Load at Partial Load
l The throttle valve (6) is partially opened or fully opened.
The air flows very rapidly through the vent line(5)s
connection(D) and the intake air duct when full-load at partial
load.
Consequently, most of the low-by gases are supplied to the
combustion chamber through the timing gear case
cover(15), chain housing(17), oil separation chamber(3),
vent line(5), throttle valve(6), and intake manifold(8).
ALTERNATOR
1 Bolt (M8 X 40, 3 pieces) ................. 22.5-27.5 Nm 3 Bolt (M8 X 85, 1 piece) ................... 22.5-27.5 Nm
2 Bolt (M8 X 70, 2 pieces) ................. 22.5-27.5 Nm 4 Alternator Bracket

1. Remove the drive belt.
3. Unscrew the alternator carrier bolts (1,2,3) and remove the
carrier (4).
Installation Notice
Notice
Apply 3Nm of torque when mounting the bolt (1); apply 25 ±
2.5Nm of torque when mounting the bolts (2), and (3); and
then tighten the bolt (1) with 25 ± 2.5Nm of torque.
reverse order.
POWER STEERING PUMP AND A/C BRACKET

Preceding Work : Removal of cooling fan and shroud
1 Nut ................................................. 35.2-28.8 Nm 9 Washer

2 Washer 10 Bolt (M8 X 105,4 pieces) ................ 22.5-27.5 Nm
3 Belt Pulley 11 A/C Compressor
4 Bolt (M8 X 91, 2 pieces) ................. 22.5-27.5 Nm 12 Bolt (M8 X 50, 5 pieces, M8 X 80,
5 Power Steering Pump 5 pieces) ........................................ 22.5-27.5 Nm
6 Bracket 13 A/C Bracket
7 Washer 14 Vent Hose
8 Bolt (M8 X 20, 2 pieces) ................. 22.5-27.5 Nm 15 Bracket Gasket ...................................... Replace
1. Remove the belt pulley after removal of poly v-belt.
Installation Notice
Notice
Pull the tensioning pulley counterclockwise as shown in the
figure.
2. Disconnect the hydraulic pipe of the power steering pump

and drain the oil.
3. Unscrew the bolts (arrows) and remove the steering pump.

Installation Notice
4. Remove the compressor after disconnecting the wiring

connector and refrigerant pipe of A/C compressor.
Notice
Discharge all the refrigerant before removing the pipes.
5. Disconnect the vent hose from the A/C bracket.
6. Unscrew all the mounting bolts (arrows) and remove the

A/C bracket and the gasket.
Installation Notice

reverse order.
10. Check the oil leakage by operating the engine after
installation.
HYDRAULIC ENGINE MOUNTING INSULATOR

Service Data
Sectional View
1 Rubber Body 9 Lower Orifice

2 Brackek 10 Upper Orifice
3 Core 11 Diaphram
4 Lower Bolt 12 Cover Plate
5 Rubber Plunger 13 Upper Bolt
6 Plunger Plate 14 Flange Bolt
7 Rubber 15 Rivet
8 Plate 16 Fluid
1 Upper Nut
2 Hydraulic Installer ................. 62~93 Nm
3 Lower Nut ............................. 28~47 Nm
Removal and Installation Procedure

1. Unscrew the upper nut(1) on engine mounting and remove
the engine.
Installation Notice
2. Unscrew the lower nut(3) and remove the hydraulic engine

mounting insulator.
Installation Notice
Notice
If the insulator is spotted with oil, replace the hydraulic
insulator assembly.
reverse order.
POLY V-BELT
1 Poly V-belt (2,155 mm) 3 Belt Tensioner

2 Belt Tensioning Pulley

1. Release the belt tension by turning the stud on the cap with
12 sided wrench or spanner counterclockwise.
Notice
Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt after prying the tensioning pulley.
Poly V-belt Arrangement
1 Belt Tensioning Pulley 5 Alternator Pulley

2 Crankshaft Belt Pulley 7 Power Steering Pump Pulley
3 A/C Compressor Pulley 8 Water Pump Pulley
TENSIONING DEVICE
Preceding Work : Removal of tensioning device shock absorber
1 Bolt (M8 x 75, 2 pieces) + 3 Tensioning Device

Washer .......................................... 22.5-27.5 Nm 4 Stud bolt
2 Bolt (M8 x 25, 1 pieces) + 5 Tensioning Arm
Washer .......................................... 22.5-27.5 Nm

1. Turn the stud bolt to counterclockwise.
2. Insert the pin (111 589 01 15 00) into the hole in tensioning
arm.
3. Unscrew the bolts (1, 2) and remove the tensioning device.
Installation Notice

reverse order.
TENSIONING DEVICE SHOCK ABSORBER
1 End Cover 5 Tensioning Device

2 Nut ................................................. 40.5-49.5 Nm 6 Bolt (M8 X 35) + Washer ................ 22.5-27.5 Nm
3 Tensioning Pulley 7 Shock Absorber
4 Bolt (M8 X 25) + Washer ................ 22.5-27.5 Nm

1. Remove the end cover (1).
2. Remove the nut (2) and remove the tensioning pulley (3).
Installation Notice
3. Unscrew the bolts (4,6) and remove the shock absorber

(7).
Installation Notice
Tightening Torque 22.5-27.5 Nm
POLY V-BELT INSPECTION

l Make marks on the belt with chalk.
l Rotate the engine and check the belt for damage.
Notice
If one of the following types of damages is found, replace
the belt.
1. Rubber lumps in the base of rib.

3. Pointed rib.
4. Belt cord visible in the base of rib.
7. Rib detached from the base of belt.
8. Splits across the rib.

9. Sections of rib torn out.
10. Splits across several ribs.

11. Splits across the back of the belt.
CYLINDER HEAD COVER
1 Ignition Coil Cover 4 Cylinder Head Cover

2 Spark Plug Connector 5 Gasket ................................................... Replace
3 Bolt (M6 X 45 : 4 pieces, M6 X 60 :
6 pieces) ............................................. 10 ± 1 Nm
1. Remove the intake air duct.
Installation Notice
2. Remove the ignition coil cover.

Installation Notice
Notice
Release 3 screws from the ignition cover and remove the
cover for M161 Engine coil.
3. Remove the spark plug connector and ignition cable.

CYLINDER HEAD FRONT COVER

Removal of thermostat housing assembly
Removal of engine hanger bracket
1 Bolt (M6 X 16, 3 pieces) ......................... 9-11 Nm 6 Front Cover (E20 : M161.943)
2 Camshaft Adjuster 7 Sleeve
3 Bolt (M8 X 35, 2 pieces) ................. 22.5-27.5 Nm 8 O-ring .................................................... Replace
4 Bolt (M6 X 22, 6 pieces) ......................... 9-11 Nm 9 Thermostat Housing
5 Front Cover (E23 : M161.973)

1. Disconnect the camshaft adjuster connector and remove
the camshaft adjuster (E23 engine only).
Installation Notice
Installation Notice
Tightening Torque (3) 22.5 - 27.5 Nm
Tightening Torque (4) 9 - 11 Nm

Apply the sealant at the mating surface of the cylinder head
and the front cover.
3. Remove the O-ring.
Installation Notice
Replace the O-ring with new one and apply the sealant.
reverse order.
CYLINDER HEAD
Removal of intake manifold
Removal of cylinder head lower line (intake manifold side)
1 Cylinder Head Bolt (M12 X 100, 10 pieces) 4 Camshaft Bearing cap ................... 22.5-27.5 Nm
.................................................... 1st step 55 Nm 5 Cylinder Head
2nd step 90° rotation added 6 Gasket ................................................... Replace
3rd step 90° rotation added 7 Dowel Sleeve ............................................... Note
3 Bolt (M8 X 35, 4 pieces) ................. 22.5-27.5 Nm
Tools Required
617 589 00 10 00 Wrench Socket
116 589 01 34 00 Threaded Bolt
001 589 66 21 00 Torque Wrence
104 589 00 40 00 Holder

1. Rotate the crankshaft so that the piston of number 1 cylinder
is at ATDC 20.
2. Put the pin into the camshaft bearing cap (number 1, 6).
Pin 111 589 03 15 00

camshaft sprocket.
Installation Notice

Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 85° - 95°
Notice
The flange bolt is designed to be used only once, so always
6. Remove the in take camshaft sprocket (E20 engine).
7. Remove the camshaft adjuster (E23, M161.970 engine).
Installation Notice (Flange Bolt)
1st step 18 - 22 Nm
Tightening Torque
2nd step 85° - 95°
Notice
1 Flange Shaft
2 Flange Bolt
3 Campression Spring
4 Adjust Piston
5 Camshaft Sprocket
6 Seal Cover
7 Nut
8. Remove the guide rail pin using the sliding hammer (02)
and the threaded pin (03).
Notice
Apply the sealant on guide rail pin when installation.
9. Unscrew the bolts (A).

Installation Notice
Bolt (A) : (M8 X 35, 4 pieces)

10. Remove the cylinder head bolts in the reverse order of
the numerics (No.10 ® No.1).
Installation Notice
Tighten the bolts as numerical order with specified torque
(No.1 ® No.10).
1st step 55 ± 5 Nm
Tightening Torque 2nd step + 90°
3rd step + 90°
Notice
Operate during engine cooling.
11. Remove the No. 1 bearing cap of the exhaust camshaft.

Installation Notice
12. Install the special tool (05) on the bearing cap removed
place and hook the engine hoist into them and remove
the cylinder head carefully.
Holder 104 589 00 40 00
1 Cylinder Head Bolt

2 M8 X 35 Bolt & Washer
3 Bearing Cap
4 Engine Hoist
5 Gasket
6 Hanger Bracket
13. Check the cylinder head mating surface and clean the
crankcase head bolt mounting hole.
14. Replace the cylind head gasket with new one.
15. Check the length of the cylinder head bolt.
When New 100 mm
Tightening Torque
Max. Length 105 mm
Notice
Replace the bolt if the measured length exceed the max.
length.
reverse order.
TIMING GEAR CASE COVER

Preceding Work : Removal of viscous clutch
Removal of tensioning device
Removal of water pump
Removal of oil filter element
Removal of oil pan
Removal of alternator bracker
1 Bolt (M8 X 60, 3 pieces) ................. 22.5-27.5 Nm 4 Timing gear case cover
2 Bolt (M8 X 75, 1 piece) ................... 22.5-27.5 Nm 5 O-ring
3 Seal 6 Sleeve
Tools Required
116 589 01 34 00 Threaded Bolt

1. Remove the power steering belt pulley and A/C compressor
bracket.
2. Remove the oil line from power steering pump.
3. Rotate the crankshaft so that the piston of number, cylinder
is at ATDC20°

camshaft sprocket.
Installation Notice
6. Remove the intake and exhaust camshaft sprocket

(remove the camshaft adjuster assembly in E23 engine).
Installation Notice
1st step 18 - 22 Nm
Tightening Torque
2nd step 85° - 95°
Notice
7. Remove the guide rail pin using the sliding hammer (02)
and the threaded pin (03).
Notice
Apply the sealant on guide rail pin when installation.

Threaded Pin 116 589 02 34 00
8. Unscrew the bolts (A).
Installation Notice
9. Remove the belt pulley and vibration damper.

Installation Notice (Center Bolt)
1st step 180 - 220 Nm
Tightening Torque
2nd step 80° - 100°
10. Unscrew the bolts (1, 2) on timing gear case cover and
remove the timing gear case cover.
Installation Notice
Notice
Be careful not to damage the cylinder head gasket.
11. Remove the radial shaft seal
Notice
Installation note replace the seal with new one.
12. Clean the timing gear case cover and crankcase sealing
surface.
13. Replace the O-ring with new one and apply the sealant on
the sealing surface.
Notice
Be careful not to stain the oil chamber of chain tensioner
with the sealant.
14. Installation should follow the removal precedure in the
reverse order.
15. Warm up the engine and check for oil leaks.
CRANKSHAFT SEALING REAR COVER

Preceding Work : Removal of the automatic transmission drive plate or flywheel
1 Bolt (M6 x 20, 6 pieces) ......................... 9-11 Nm 4 Sleeve

2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......................... 9-11 Nm
3 Rear Cover 6 Washer
Tools Required
601 589 03 43 00 Sleeve

1. Unscrew the bolts (1) and (5) and remove the closing cover
by pulling the rear cover lug (arrows).
Notice
2. Clean the sealing surface of the crankcase and the rear

sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft seal.
Notice
6. Using the special tool, press the radial shaft seal and the
rear cover.
7. Tighten the rear cover bolt (1) and then tighten the oil pan
bolt (5) as specified and remove the special tool.
Installation Notice
Tightening Torque(Bolt 1,5) 9 - 11 Nm
Seal Assembler 601 589 03 43 00

BELT PULLEY AND VIBRATION DAMPER

Preceding Work : Removal of cooling fan and viscous clutch
Removal of fan shroud
1 Center Bolt 5 Vibration Damper Assembly

(M18 X 55) ....................... 1st step 200-220 Nm 6 Key
2nd step 90° + 10° rotation added
2 Vibration Damper Disk
Components

3 Vibration Damper and Pulley Assembly
4 Key
6 Timing Gear Case Cover
7 Crankshaft Sprocket (Camshaft Driven)
8 Crankshaft Sprocket (Oil pump Driven)
9 Crankshaft
10 Oil Pan
11 Oil Pan Gasket
12 Oil Pan Mounting Bolt (M6 x 22)

Permissble Deviation of The Vibration Damper Radial Runout 0.6 mm
Axial Runout 0.6 mm
Tools Required
103 589 00 33 00 Puller
001 589 74 21 00 Puller
602 589 00 40 00 Engine Lock

1. Adjust the piston of number 1 cylinder to the TDC.
2. Remove the start motor and install the engine lock to the
flywheel ring gear.
3. Remove the center bolt.
Installation Notice
Tightening Torque 1st step 180 - 220 Nm

2nd step + 90°
Engine Lock 602 589 00 40 00
4. Remove the vibration damper assembly using the puller.

reverse order.
Notice
If possible, don’t separate the vibration damper and the
pulley.

Preceding Work : Removal of belt pulley and vibration damper

............................... 1st step 200-220 Nm
2nd step 90° +10°
3 Sleeve (Special Tool)
5 Key
Tools Required
601 589 03 14 00 Sleeve
Notice
2. Coat the radial sealing lip with engine oil.
3. Using the sleeve, assemble the radial seal .
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
1st step 200 - 220Nm
Tightening Torque
2nd step 90° + 10°
5. Remove the sleeve and install the belt pulley and the
vibration damper.
CRANKSHAFT REAR RADIAL SEAL

Preceding Work : Removal of flywheel or drive plate
1 Special Tool 3 Crankshaft Rear Seal

2 Special Tool
Tools Required
601 589 03 43 00 Sleeve
Replacement Proceudre
Notice
2. Install the special tool (2) to the crankshaft.
3. Apply the engine oil on the special tool (2).
Notice
4. Install the radial seal on the inner parts assembler.
5. Press in the special tool (1) until the radial seal is stopped.
CRANKSHAFT
Removal of timing gear case cover
Removal of crankcase sealing rear cover
Removal of oil pan
Removal of oil pump
1 Bearing Cap Bolt

(M8 X 55-10 pieces) ............ 1st step 50-60 Nm
2nd step 90°+5° rotation added
2 Bearing Cap
3 Upper Main Bearing
4 Lower Main Bearing
5 Upper Thrust Bearing
8 Crank Shaft
Arrangement of the Thrust Bearing and the Main Bearing
1 Upper Main Bearing A Crankcase Side

2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side)
3 Crankshaft
4 Lower Main Bearing
1 - 8 Weight Balance/Color Marking Point

j1 - j5 Journal Main Bearing #1 - #5
l Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6

, 8 , and it indicates the diameter of crankshaft journal
by color as below.
Color Dot Marking Crankshaft Journal Diameter (mm)

Blue 57.960 - 57.965
Yellow 57.955 - 57.960
Red 57.950 - 57.955
White 57.945 - 57.950
Violet 57.940 - 57.945
Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating surface
to oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing
according to the punching mark when repaired.
Punching Mark Bearing Color Selected

· Blue
·· Yellow
··· Red
2. Crankshaft Bearing Cap Side

Select the crankshaft main bearing according to the
marking letter on the crankshaft main journal when
repaired.
Marking Letter Bearing Color Selected
B Blue
Y Yellow
R Red
W White
V Violet
Service Data Unit : mm

Crankshaft Crankshaft Crankshaft Connecting Rod Connecting
Crankshaft Standard Bearing Jour- Bearing Journal Width Bearing Journal Rod Bearing
and Repair Size nal Diameter Diameter at fit bearing Diameter Jourmal Width
Standard size 57.950-57.965 58 24.50-24.533 47.94-47.96 27.958-28.042
1st repair size 57.700-57.715 47.75
2nd repair size 57.450-57.465 47.50
- - -
3rd repair size 57.200-57.215 47.25
4th repair size 56.950-56.965 47.00
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap.
Installation Notice

not change each other.
l Coat the bearing shell with engine oil.
l Install the bearing cap according to the consecutive
number.
2. Unscrew the crankshaft bearing cap bolts and separate

the upper and lower bearing shells and thrust washers.
Installation Notice
l Remove the bearing cap from front (pulley side) to

rear.
not change each other and coat with engine oil.
l The oil grooves (arrows) in the thrust washers must
face outward and insert the thrust bearing into the
bearing cap.
l There are five kinds of thrust washers by thickness. Part No. : 601 030 00 62 2.15 mm
Select the proper washer when repaired. Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
3. Remove the crankshaft. Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
reverse order.
5. After completion of the installation, check for the rotating
condition of the crankshaft.
Installation Notice
l Make sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly
installed, the projected part (arrow) locates in the left
side (intake manifold side).
l Assemble so that the projected part of the cap and
crankcase face the same direction.
Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated

on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft

bearing.
Notice
l Measure at 2 points (1, 2).
l Measure ‘A’,‘B’and ‘C’ as shown. If average value of
‘B’ and ‘C’is less than value ‘A’, then the average value
of ‘B’ and ‘C’ is actual average value. If average value
of ‘B’ and ‘C’ is more than value ‘A’is actual average
value.
4. Measure and record the diameter of the crankshaft

bearing journal.
Notice
l Record the mean value when measured at 3 points
(A, B, C).
l Measure the inner diameter of bearing and the
diameter of journal and if it is out of the standard data,
replace the bearing shell.
Service Data Standard (Crankshaft Main Bearing Gap)
Main Bearing Journal Static condition :0.015-0.039
( NO. 1, 5, 7) Radial Dynamic condition: 0.031-0.051
(Consider the expansion 0.011-0.016)
Axial 0.010 - 0.254
(Connecting Rod Bearing Gap)

Connecting Rod Bearing Radial 0.020 - 0.065
FLYWHEEL/DRIVEN PLATE
Preceding Work : Removal of manual or automatic transmission
1 Flywheel Mounting Bolt 3 Driven Plate (A/T)

(M10 x 22, 8 pieces) ................ 1st Step 45 Nm 4 Dowel Pin
2nd Step 90°+10° 5 Flywheel (M/T)
2 Plate
Service Data Standard (Stretch Bolt)

Nominal Size D - M x 1.5
Stretch Side Diameter d When New 8.5 - 0.2 mm
Min. Diameter 8.0 mm
Bolt Length L When New 21.8 - 22.2 mm
Tightening Torque 1st step 50 Nm, 2nd step 90°
1. Unscrew the stretch bolt.
Installation Notice
1st step 45 Nm
Tightening Torque
2nd step 90°+5°
l Replace the bolt when the stretch side diameter (d) of

the flywheel mounting bolt is less than 8.0mm.
l For the stretch bolt tightening, keep the socket wrench
and Tommy-bar to be 90° and tighten as specified.
2. Remove the flywheel for manual transmission vehicles,

or the driven plate (3), and plate (2) for Auto. transmission
vehicle.
reverse order.
Sectional View
1 Oil Pan
2 Cover
3 Radial Seal
4 Bolt
5 Crankshaft
6 Dowel Pin
7 Washer (Thickness : 3.5 mm)
8 Washer
9 Bolt
10 Front Drive Plate
11 Rear Drive Plate
12 Rivet
13 Segment
14 Ring Gear
CAMSHAFT ADJUSTER
1 Bolt (M6 X 16, 3 pieces) ......................... 9-11 Nm 11 Flange Bolt

2 Cylinder Head Front Cover (M7 X 13, 3 pieces) ................. 1st Step 20±2 Nm
3 Bolt ........................................................... 35 Nm 2nd Step 90° ± 5° Rotation Added
4 Armature 12 Flange Shaft
5 Roll Pin 13 Compression Spring
6 Nut (M20 X 1.5) .................................... 60-70 Nm 14 Control Piston
7 Seal Cover 15 Circlip
8 Camshaft Sprocket 16 Oil Gallery
9 Adjust Piston 17 Straight Pin
10 Conical Spring 18 Intake Camshaft
Y49 Magnetic Actuator (2-pin connector)
1. Turn the crankshaft and position the n0.1 cylinder piston at
ATDC 20°.
Notice
Turn the crankshaft in the direction of engine rotation.

and the timing chain.
4. Insert the insert pin into the no.1 and no.6 bearing cap hole
on camshaft to secure intake and exhaust camshaft.
6. Unscrew the exhaust sprocket bolt and remove the exhaust

camshaft sprocket.
Installation Notice
1st step 20 Nm
Tightening Torque
2nd step 90°
Notice
7. Unscrew the bolt (3) from the armature (4) and remove
the roll pin, and remove the armature.
Installation Notice
8. Unscrew the nut (6) and remove the seal cover (7).
Installation Notice
Notice
Put the locking slot of nut toward armarture.
9. Take off the timing chain from intake camshaft sprocket.
10. Remove the cover (7), adjuster piston (9) and conical
spring (10) from intake camshaft sprocket.
11. Unscrew the bolt (11) and remove the flange shaft.
Installation Notice
1st step 20 Nm
Tightening Torque
2nd step + 95°
Notice
reverse order.
13. Check and adjust the camshaft timing.
CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
1st step 20 Nm
Tightening Torque
2nd step + 90°
Notice
C. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
16. Flange Shaft
18. Control Piston
22. Intake Camshaft
Exhaust Camshaft Sprocket Bolt

1st step 20 Nm
Tightening Torque
2nd step + 90°
Notice
E. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
13a. Camshaft Sprocket
22a. Exhaust Camshaft
CAMSHAFT
Removal of camshaft adjust actuator and cylinder head front cover
1 Bolt (M7 X 13, 3 pieces) ......... 1st Step 18-22 Nm 4b Camshaft Adjuster and Camshaft Sprocket (E23)
2nd Step 90°+ 5° Rotation Added 5 Bearing Cap Bolt (20 pieces) ......... 22.5-27.5 Nm
2 Exhaust Camshaft Sprocket 6 Camshaft Bearing Cap
3 Timing Chain 7 Wrench (Special Tool)
4a Intake Camshaft Spocket (E20)
Tools Required
104 589 01 01 00 Spanner

1. Turn the crankshaft and position the no.1 cylinder piston at
ATDC20°.

and the timing chain.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
4. Remove the exhoust camshaft sprocket.

Installation Notice
1st step 35 - 45 Nm
Tightening Torque
2nd step 85° - 95°
Notice
5. Take off the timing chain from intake camshaft sprocket,
and secute it not to fall down into the timing gear case.
6. Using the wrench (7), turn the camshaft until there is no

resistence in camshaft bearing area.
7. Remove the bearing cap, and remove the intake and the
exhaust camshaft.
Installation Notice
Notice
Check the numbers on the bearing cap not to be miked
up.
8. Apply the engine oil on the valve tappet and camshaft

bearing.
reverse order.
Notice
l Base circle of cam should cantact with the valve tappet.
l Install the camshaft bearing caps according to the
numbers on the cylinder head cast and bearing cap.
M161 ENGINE MECHANICAL 1-1B-69
CAMSHAFT TIMING POSITION

1 Insert Pin (f 6.5mm, Special Tool) 5 Exhaust Camshaft Sprocket

2 Intake Camshaft Sprocket 6 Bolt (M7 X 13, 3 pieces) ......... 1st step 20 ± 2 Nm
3 Camshaft Bearing Cap 2nd step 90° ± 5° rotation added
4 Timing Chain 7 Strate Pin
Tools Required
104 589 01 01 00 Spanner
111 589 03 15 00 Insert Pin
Inspection Procedure
1. Position the NO.1 cylinder piston to ATDC 20° by turning
the crankshaft
Notice
When the ATDC 20° mark on vibration damper is aligned
with timing gear case cover, the intake and exhaust cam of
cylinder will make the slope to the center and will face up.
In this way, the insert hole in NO.1 and NO.4 camshaft
bearing cap will match in line with the flange hole for
camshaft sprocket.
2. Check the timing as below procedure;
- Check if the insert pin (111 589 03 15 00) can be inserted
into the NO.1 and NO.4 bearing cap hole.
- At this condition, check if the ATDC 20° mark on vibration
damper aligns with the marker on the timing gear case.
Adjustment Procedure
1. Position the NO.1 cylinder to ATDC 20° .
4. Adjust the timing position with inserting the insert pin
(f6.5mm, 111 589 03 15 00) into the NO.1 and NO.4
camshaft bearing cap hole and flange hole while rotating
the camshaft by using wrench (104 589 01 01 00).
5. Install the chain to the intake camshaft sprocket.
6. Install the chain to the exhaust camshaft sprocket and
tighten the bolt.
Installation Notice
1st step 20 Nm
Tightening Torque
2nd step + 90°
Installation Notice
Tightening Screw plug 40 Nm

Torque Tensioner assembly 80 ± 8 Nm
8. Check the camshaft timing.

VALVE SPRING
1 Valve Tappet Assembly 7 Connecting Hose

2 Valve Cotter 8 Thrust Piece
3 Upper Retainer 9 Slide
4 Valve Spring .......... Check, Replace if necessary 10 Adjust Bolt
5 Valve Stem Seal 11 Lever Pusher
6 Lower Retainer 12 Supporting Bar
Tools Required
111 589 18 61 00 Lever Pusher
111 589 25 63 00 Thrust Piece

1. Place the supporting bar (12) and the slide (9) at the
camshaft bearing cap (Nos 1 & 7/8&14) and tighten them
with the bearing cap bolt.
Installation Notice
2. Turn the crankshaft to position the each cylinder piston at

TDC.
Mark on The Vibration Damper Cylinder
OT 1, 4
UT 2, 3
Notice
l Remove the valve spring only at TDC.
l Always rotate the crankshaft by holding the chain to
prevent from timing chain damage and tangling, and for
smooth rotation.
3. Remove the valve tappet (1) using the magnetic finger.
4. Install the leakage tester connecting hose to the spark plug
hole.
5. Install the engine lock to the ring gear to prevent the

crankshaft from rotating.
6. Blow up with compressed air.
8. Install the lever pusher (11) and the thrust piece (8) to the
slide (9).
Lever Pusher 111 589 18 61 00
9. Mount the thrust piece (8) vertically to the valve spring

retainer (3).
10. Make the thrust piece (8) and the slide (9) perpendicular
to each other.
11. Secure the slide (9) by turning the adjust bolt (10).
12. Press the valve spring (4) by using the lever pusher (11).
13. Remove the valve cotter (2) using either the pincette (13)
or magnetic finger.
14. Remove the upper retainer (3) and the valve spring (4).
15. Remove the valve stem seal and replace if necessary.
Notice
Check the valve stem seal and replace if necessary.
16. Remove the lower retainer (6).
Notice
Check the retainer for damages and replace with a new
one if necessary.
reverse order.
Test (Upper and Lower Valve Tappet and Valve
Cotter)
l Upper Valve Spring Retainer
(d) 8.5
Size (mm)
(D) 12.3
l Lower Valve Spring Retainer
Thickness (mm) (a) 0.8 - 1.0
l Valve Cotter
(B) 9.0
Size (mm)
(H) 9.2 - 9.8
VALVE STEM SEAL

1 Drift (Special Tool)

2 Valve Stem Seal
3 Protective Sleeve
Tools Required
104 589 00 37 00 Pliers
119 589 00 43 00 Drift
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
Pliers 104 589 00 37 00
2. Coat the valve stem seal with oil and assemble it with the
protective sleeve.
3. Insert the valve stem seal by pressing it with the drift.
Drift 119 589 00 43 00

CHAIN TENSIONER
1 Screw Plug ................................................ 40 Nm 5 Snap Ring

2 Seal 6 Thrust Pin
3 Filler Pin 7 Chain Tensioner Housing ..................... 72-88 Nm
4 Compression Spring 8 Seal
Removal Procedure
1. Position the number 1 cylinder to ATDC 20°.
Notice
Remove the oil filler cap at adjustment position, and check
whether the intake camshaft cam’s lobe (arrow) stays in the
upper side.
2. Cover the alternator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the screw
plug, reinstall after completely removing the chain tensioner.
If the chain tensioner is tightened again without completely
reducing its tension, then the snap ring doesn’t return to
the original position and the tension gets excedded.
4. Carefully unscrew the screw plug (1), and remove the seal
(2).
Notice
l For the removal of screw plug, be careful that it can be
jumped out due to the force of compression spring.
l Remove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring (4),
snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).
1. Connect the thrust pin (6) and the snap ring (5) to the chain
tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust pin far
enough so that it doesn’t protrude at the chain tensioner
housing.
2. Install the chain tensioner housing (7), Thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
3. Insert the compression spring (4) with the filler pin (3) into
chain tensioner housing.
4. Lightly apply the grease to the seal (2) and install the screw
plug (1).
Installation Notice
5. Check for leaks by operating the engine.
Sectional View
1 Screw Plug 13 Chain Tensioner Housing

2 Ball (Nonreturn Valve) 14 Seal
3 Compression Spring 15 Timing Gear Case Cover
4 Ball Guide 16 Cylinder Head
5 Seal (Aluminum) 17 Bolt / Washer
6 Filler Pin 18 Tensioning Rail
7 Compression Spring 19 Cylinder Head Gasket
8 Snap Ring 20 Timing Chain
9 Thrust Pin 21 Tensioning Rail Base (Sliding Surface)
10 Ball (Nonreturn Valve) A Oil Supply Hole
11 Compression Spring B Chain Tensioner Oil Storage Hole
12 Thrust Piece
TIMING CHAIN
1 Pin 5 Link
2 New Timing Chain 6 Center Plate
3 Timing Chain (Used) 7 Outer Plate
4 Wedge
Tools Required
000 589 58 43 00 Chain Assembly
103 589 01 63 00 Rivet Set
1. Position the NO.1 cylinder to ATDC 20°.
2. Insert the pin to the intake and exhaust camshaft flange.

4. Mount the wedges to both sides of the camshaft sprocket

as shown in the figure.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket with
the grinder.
6. Remove the outer plate (7) with the screw driver and
remove the link (5).
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with the
link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.
12. Place the outer plate (7, thickness 1.2mm) inside the thrust
piece (b).
13. Install the assembly tool above the link and tighten the
spindle (c) until a block is felt.
14. Place the assembly tool.
15. Replace the thrust piece (b) as shown in the figure.
16. Install the assembly tool to the link pin and tighten the
spindle (c).
17. Rivet the link pin.
Check the condition and it again if necessary.
Installation Notice
Screw Plug 40 Nm
Tightening Torque

TENSIONING RAIL
1 Sliding Rail Pin 3 Timing Gear Case Cover

2 Sliding Rail

1. Remove the timing gear case cover (3).
Notice
Be careful not to damage the gasket.
2. Remove the sliding rail (1) from the sliding rail pin (2).
Notice
l Replace the plastic guide (2) if it is damaged.
l For installation, exactly align the plastic guide (2) with
the sliding rail (1).
reverse order.

1 Bolt (M6 X 45, 2 pieces) .................. 9-11 Nm

2 Guide Rail

1. Position the number 1 cylinder to ATDC20° guide rail.
2. Install the pin (special tool : 111 589 03 15 00) into the no.1
and no.6 bearing cap hole.
Installation Notice
Screw Plug 40 Nm
Tightening Torque
4. Unscrew the bolt (1) and remove the guide rail.

Installation Notice

reverse order.
CRANKCASE GUIDE RAIL

1 Guide Rail Pin 3 Timing Gear Case Cover

2 Guide Rail

1. Remove the timing gear case cover (3).
Notice
Be careful not to damage the gasket when removing/
installing the timing gear case cover.
2. Remove the guide rail (2) from the guide rail pin(1).
Notice
l Replace the plastic guide (2) if damaged.
l Connect the plastic guide (2) and the guide rail (1) by
aligning them accurately when installing.
reverse order.
CRANKSHAFT SPROCKET
Removal of tensioning rail
Removal of crank case guide rail
1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer .......... 29-35 Nm
2 Oil Pump Chain Spring 7 Oil Pump Sprocket
3 Oil Pump Chain Bushing (Pin) 8 Oil Pump
4 Crankshaft Sprocket 9 Oil Pump Roller Chain
5 Key 10 Timing Chain
Tools Required
615 589 01 33 00 Caulking Bolt

1. Put the assembly mark at the crankshaft sprocket (4) and
the timing chain (10) with the paint (arrow).
Installation Notice
Align the assembly marks on cranshaft sprocket and timing
chain. Also, align the assembly marks on camshaft sprocket
and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket (7)
from the oil pump.
Installation Notice
3. Remove the oil pump roller chain (9).

4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (3), and the oil pump chain spring (2).
5. Remove the crankshaft sprocket (4) using the puller (04,
special tool).
Notice
l Make sure not to lose the crankshaft pulley key (5) when
removing.
l Install the crankshaft sprocket (4) after warming it up.
reverse order.
Caulking (04) 615 589 01 33 00

PISTON
Removal of oil pan
Removal of oil pump
1 Connecting Rod Bearing Cap 4 Piston

2 Connecting Rod 5 Snap Ring
3 Connecting Rod Bolt 6 Piston Pin
(M9 x 52, 8 pieces) ...................... 1st step 40 Nm
2nd step 90° +5°
Tools Required
001 589 72 21 00 Torqued Wrench
Removal Procedure
1. Unscrew the connecting rod bolt (3) and remove the cap.
2. Remove the connecting rod and the piston upward.
Notice
Make sure that the bearing cap and shell are not changed
each other.
Notice
Remove the snap ring using a clean cloth as shown in the
right picture so that the piston, piston ring, and the snap
ring don’t get damaged.
1. Check the piston ring gap and apply the engine oil to the
piston pin and the connecting rod bushing.
2. Connect the piston and the connecting rod by pressing in
the piston pin (6) and install the snap ring to the groove.
3. Clean the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and the piston and coat them
with engine oil.
4. Install the piston ring using the tensioning strap(000 589
04 14 00).
5. Install the piston so that the arrow on the piston head faces
to the forward of the vehicle.
6. After aligning the connecting rod and the bearing cap mark
(// or a number), tighten the bolts.
Installation Notice
1st step 35 - 45 Nm
Tightening Torque
2nd step 90°+5°
Apply the engine oil to the bearing cap upper and lower
bearing shells.
7. Check if the crankshaft rotates without any trouble by rotating
it.
CONNECTING ROD
1 Connecting Rod Bushing

2 Oil Gallery
3 Balance Weight
4 Connecting Rod Bolt
(M9 x 52, 8 pieces) ............1st step 40 Nm
2nd step 90°
5 Fit Sleeve
6 Upper Connecting Rod Bearing
7 Lower Connecting Rod Bearing
8 BearingShell Lug
9 Marking [Indication(//) or Numbers]

Distance (L) from The Connecting Rod Bearing to Bushing Bore Center E20 : 154 mm
E23 : 149 ± 0.05 mm
Width of The Connecting Rod (B) at Bearing Bore 21.940 - 22.000 mm
Width of The Connecting Rod (b) at Bushing Bore 21.940 - 22.000 mm
Basic Bore at The Bearing Shell (D1) 51.600 - 51.614 mm
Basic Bore at The Bushing (d1) 24.500 - 24.571 mm
Bushing Inner Diameter (d) 22.007 - 22.013 mm
Clearance Between The Piston Pin and The Bushing 0.007 - 0.018 mm
Peak-to-valley Height of Connecting Rod Bushing on Inside 0.005 mm
Permissible Wwist of Connecting Rod Bearing Bore to 0.1/100 mm
Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod 0.045/100 mm
Bearing Bore to Connecting Rod Bushing Bore
Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore from 0.01 mm
Concentricity
Permissible Difference of Each Connecting Rod in Weight 0.4 g
Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614mm, replace
the bearing or check the connecting rod.
2. Check connecting rod bolts.
Length When New (L) 51.7 - 52 mm

Max. Length (L) 52.9 mm
Tightening Torque 1st step 40 + 5 Nm
2nd step 90°+10°
Notice
If the length exceeds max. length, replace it.
3. Check the assembly mark(indication//or number:arrow) of

the connecting rods and the bearing cap when installing.
Notice
l Make sure it doesn’t exceed over 4g with other
connecting rods when replacing the connecting rods.
l Check if the connecting rod and the bearing cap are
accurately seated on the groove when replacing the
bearing.
PISTON RING
1 Piston Compression Ring (Top Ring)

2 Piston Compression Ring (2nd Ring)
3 Piston Oil Ring
4 -
5 Spacer
6 Side Rail
Tools Required
1. Measure the piston ring’s gap.
End Gap of The Groove 1 0.20 - 0.40 mm
Piston Ring Groove 2 0.20 - 0.40 mm
Groove 3 0.20 - 0.45 mm
Gap Between Groove 1 0.028 - 0.060 mm
The Piston and Groove 2 0.010 - 0.045 mm
The Piston Ring
Groove 3 0.010 - 0.045 mm
Notice
If out of specification, replace the piston ring.
2. Remove the piston ring with a pliers.
Clamping Strap 000 589 51 37 00
3. For installation, position the piston ring to be the ‘TOP’

mark on the piston ring upward and arrange the piston ring
ends to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away from
the ring end.
OIL PAN
1 Bolt 5 Bolt
2 Bolt 6 Oil Pan
3 Bolt 7 Gasket
4 Bolt
1. Remove the drain plug and drain the oil completely.

2. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then apply
the sealant.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine.
M8 X 40, 4 pieces
M6 X 35, 1 pieces
M6 X 100, 2 piece
M6 X 85, 3 pieces
u M6 X 20, 20 pieces
Oil Circulation
1 Oil Strainer 16 Oil Supply (To Chain Tensioner)

2 Oil Pump 17 Camshaft
3 Oil Pan 18 Cam Bearing
4 Oil Non-Return Valve 19 Valve
5 Oil Filter 20 Oil Gallery (Supply Oil to Intake Tappet)
6 Oil Filter Bypass Valve 21 Oil Gallery (Supply Oil to Exhaust Tappet)
7 Main Oil Gallery 22 Ball (f 8mm)
8 Closing Ball (f 15mm) 23 Camshaft Plug
9 Crankshaft 24 Seal
10 Connecting Rod Bearing 25 Screw Plug
11 Crankshaft Bearing 26 Oil Return Gallery (Cylinder Head and
12 Connecting Rod Crankcase)
13 Piston 27 Oil Return Gallery (Crankcase)
14 Oil Spray (Piston Crown Area) 28 End Cover (f 20mm)
15 Non-Return Valve (Crankcase) 29 Oil Return Pipe
ENGINE OIL AND OIL FILTER ELEMENT
1 Oil Filter Cover .......................................... 25 Nm 4 Oil Drain Plug

2 O-ring .................................................... Replace 5 Oil Filter Bypass Valve
3 Oil Filter Element 6 Oil Filter Cap
Tools Required
103 589 02 09 00 Oil Filter Socket Wrench
1. Install the socket wrench”7” (special tool : 103 589 02 09
00) on the oil filter cover (2).
Notice
Make the screw cover removable by tightening the bolt at
the side of the socket wrench (special tool).
2. Install the wrench to the upper bolt in the socket wrench
and remove the oil cover by turning it.
3. Remove the oil filter element.
Notice
Work with a cloth under the vehicle when removing the oil
filter element to not drain the oil.
4. Remove the drain plug (1) and drain the engine oil.
Notice
Leave the oil filler cap (3) open to ease the engine oil
discharge.
5. Tighten the engine oil drain plug after cleaning it.
Installation Notice
Replace the seal washer with new one.
6. Replace the O-ring(5) in the oil filter cover with new one.
Notice
Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover (2). Install the socket
wrench “7” (special tool : 103 589 02 09 00), and then
completely tighten it.
Installation Notice
2 Oil Filter Cover

5 O-ring
6 Oil Filter Element
7 Special Tool (Socket Wrench)
9. Fill up engine oil through the engine oil filler opening.

10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.
OIL PUMP
1 Bolt (M8 X 35, 3 piece) ................... 22.5-27.5 Nm 6 Washer

2 Oil Pump 7 Sprocket (Oil Pump Drive)
3 Oil Strainer Assembly 8 Chain (Oil Pump Drive)
4 Bolt (M6 X 12, 2 pieces) ......................... 9-11 Nm 9 Plate-Baffle
(In E23 Engine, These Bolts are 10 Bolt (M6 X 12, 6 piece) ........................... 9-11 Nm
Combined with Baffle Plate) (E23 Engine Only : Baffle Plate Mounting Bolt)
5 Bolt (M8 X 20, 1 pieces) ....................... 29-35 Nm
1. Unscrew the bolt (6) from the oil pump drive sprocket and
separate the oil pump drive chain.
Installation Notice
2. Unscrew the bolts (4,5) and remove the oil strainer assembly
(3).
Installation Notice
Bolt (4) 9 - 11 Nm
Tightening Torque
Bolt (5) 9 - 11 Nm
Insert the steel gasket into the oil pump and bolt (4) mounting
surface.
3. Unscrew the six bolts (11) and remove the haffle plate.
Installation Notice
4. Unscrew the three bolt (1) and remove the oil pump.
Installation Notice
OIL PRESSURE RELIEF VALVE

1 Screw Plug ................................................ 50 Nm 3 Guide Pin

2 Compression Spring 4 Piston

1. Remove the screw plug (1).
Installation Notice
2. Remove the spring (2), guide pin (3) and the piston (4).
reverse order.
Notice
Don’t use the seal for the screw plug.
OIL NON-RETURN VALVE

1 Oil Non-Return Valve
Functions
The non-return valve prevents the oil in the chain tensioner
from drying up. In other words, it stops oil-returning in order to
prevent the oil in the chain tensioner from getting dry. As a
result, the chain tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.
OIL DIPSTICK GUIDE TUBE
1 Oil Dipstick Level Gauge 4 Bolt (M6 X 16, 1 piece) ........................... 9-11 Nm
2 Oil Dipstick Guide Tube 5 Clamp
3 O-ring

1. Pull out the oil dipstick level gauge (1).
2. Unscrew the bolt (4) and remove the oil dipstick guide
tube (2).
Installation Notice
It is very hard to remove the oil dipstick guide tube without
special tool. If it is not necessary, do not remove the guide
tube.
reverse order.
4. Check for leaks by starting the engine.
UNIT REPAIR
CORE PLUGS IN CRANKCASE
Preceding Work : Draining of the coolant
1 Core Plug ............................................... Replace

Tools Required
102 589 00 15 00 Drift
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes out
using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.

Notice
Wait for about 45minutes before filling the coolant so that
the Loctite 241 hardens.
CYLINDER BORE
Group Code Letter and Cylinder Bore Size

Engine Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm)
A A or X f 90.906 - f 90.912
X A, X or B f 90.906 - f 90.912
E23 B X or B f 90.912 - f 90.918
X+5 X+5 f 90.950 - f 90.968
X + 10 X + 10 f 91.000 - f 91.018
A A or X f 89.900 - f 90.906
X A, X or B f 89.906 - f 89.912
E20 B X or B f 89.912 - f 89.918
X+5 X+5 f 89.950 - f 89.968
X + 10 X + 10 f 90.000 - f 90.018
Type Group Code Letter1) Cylinder Bore Size (mm)

Standard Size A f 89.900 - f 90.906
E20 : f 89.9 X f 89.906 - f 89.912
E23 : f 90.9 B f 89.912 - f 89.918
1st Repair Size A f 90.150 - f 90.156
B f 90.162 - f 90.168
2nd Repair Size A f 90.400 - f 90.406
B f 90.412 - f 90.418
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.

Wear Limit in Longitudinal and Transverse Direction 0.1 mm
Permissible Deviation of Cylinder Out-of-round When new 0.007 mm
Wear limit 0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm
Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm
Chamfer Angle 75°
Honing Angle 50° ± 10°
Measurement of Cylinder Bore

1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size in
axial and transverse direction at three points (1,2,3).
1,2,3 Measuring Points

A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle
CRANKCASE MATING SURFACE

Height of the Crankcase “H” (When New) 289.35 - 289.45mm
Minimum Height After Milling 289.05mm
Flatness Crankcase Upper Mating Surface 0.03mm
Permissible Deviation of Parallelism of the Axial Direction 0.1mm
Upper to Lower Mating Surface Transverse Direction 0.05mm
Peak-to-valley Height Crankcase Upper Mating Surface 0.012 - 0.009mm
Crankcase Lower Mating Surface 0.025 - 0.020mm
Chamfering Procedure
1. Chamfer angle : 75°
2. Polish the lower chamfered area evenly with a grinder after

finishing the chamfering with a suitable tool (e.g., hand milling
cutter).
CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of valves

Overall Height of Cylinder Head 135.9 - 136.0 mm
Minimum Height After Machining 135.5 mm
Flatness Axial Direction 0.08 mm
Transverse Direction 0.0 mm
Distance ‘T’ Standard Size Intake 24.21 - 24.75 mm
(Between Camshaft Bearing Exhaust 22.21 - 22.75 mm
and Valve Stem) Repair Size Intake 23.96 - 24.51 mm
Exhaust 21.96 - 22.51 mm
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.
Measurement of Mating Surface
1. Measure the height (H) of the cylinder head (refer to Service
data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard).
Universal Tool
Surface Grinding Machine Sceledum, Type RTY
Roaro
Schio/Italy
SECTION 1B3
OM600 ENGINE MECHANICAL

noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B3-2 Valve Springs (Cylinder Head Installed) . . 1B3-109
Fastener Tightening Specifications . . . . . . . . 1B3-2 Valve Stem Seals . . . . . . . . . . . . . . . . . . . 1B3-112
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1B3-4 Check and Replacement of
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1B3-4 Valve Guides . . . . . . . . . . . . . . . . . . . . . 1B3-116
Valve Seat Rings . . . . . . . . . . . . . . . . . . . 1B3-122
Maintenance and Repair . . . . . . . . . . . . . 1B3-12
Check and Machining of Valves . . . . . . . . 1B3-127
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1B3-12
Machining of Valve Seat . . . . . . . . . . . . . . 1B3-132
Engine Assembly . . . . . . . . . . . . . . . . . . . . 1B3-12
Camshaft Timing Test . . . . . . . . . . . . . . . . 1B3-137
Poly V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-21
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-139
Tensioning Device . . . . . . . . . . . . . . . . . . . . 1B3-23
Chain Tensioner . . . . . . . . . . . . . . . . . . . . 1B3-145
Poly V-Belt Alignment & Inspection . . . . . . . 1B3-26
Timing Chain . . . . . . . . . . . . . . . . . . . . . . . 1B3-147
Prechamber . . . . . . . . . . . . . . . . . . . . . . . . 1B3-29
Tensioning Rail . . . . . . . . . . . . . . . . . . . . . 1B3-151
Milling of Prechamber Sealing Surface . . . . 1B3-32
Cylinder Head Guide Rail . . . . . . . . . . . . . 1B3-152
TDC (TDC Sensor Bracket) Setting . . . . . . 1B3-35
Timing Case Cover Guide Rail . . . . . . . . . 1B3-156
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 1B3-37
Crankshaft Sprocket . . . . . . . . . . . . . . . . . 1B3-158
Timing Case Cover . . . . . . . . . . . . . . . . . . . 1B3-63
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-163
Crankshaft End Cover . . . . . . . . . . . . . . . . 1B3-71
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-169
Vibration Damper and Hub . . . . . . . . . . . . . 1B3-74
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-171
Crankshaft Front Radial Seal . . . . . . . . . . . 1B3-80
Oil Spray Nozzle . . . . . . . . . . . . . . . . . . . . 1B3-174
Crankshaft Ball Bearing . . . . . . . . . . . . . . . 1B3-82
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-175
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-83
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B3-93 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 1B3-177
Machining of Flywheel . . . . . . . . . . . . . . . . 1B3-97 Cylinder Head Pressure Leakage Test . . . 1B3-177
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . 1B3-98 Facing Cylinder Head Mating Surface . . . . 1B3-178
Hydraulic Valve Clearance Compensation Replacement of Crankcase Core Plug . . . 1B3-180
Element Check . . . . . . . . . . . . . . . . . . . . 1B3-101 Facing Crankcase Contacting Surface . . . 1B3-182
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . 1B3-103 Oil Gallery Steel Ball . . . . . . . . . . . . . . . . . 1B3-183
Valve Spring Check . . . . . . . . . . . . . . . . . 1B3-105 Cylinder Bore Measurement . . . . . . . . . . . 1B3-187
Valve Springs (Cylinder Head Removed) . 1B3-106
1B3-2 OM600 ENGINE MECHANICAL
SPECIFICATIONS
Engine Assembly
Application N·
·m
Skid Plate Bolt 28 - 47
Drain Plug Bolt 30
Coolong Fan Shroud Bolt 3-7
Control Linkage Nut 8 - 18
Clutch Linkage Cylinder Nut 20 - 34
Exhaust Manifold Bolt 30
Propeller Shaft Bolt & Nut (Axle) 70 - 80
Propeller Shaft Bolt & Nut (T/C) 81 - 84
Crankshaft Assembly
Application N·
·m
Cooling Fan Belt Pulley Bolt 10
Socket Bolt 23
Tighten The Bolt 200 / 90°
End Cover Bolt 10
Crankshaft Bearing Cap Bolt 55 / 90°
Ball Bearing 45 / 90°
Camshaft Sprocket Bolt 25 / 90°
Oil Pump Sprocket Bolt 25
Piston
Application N·
·m
Connecting Rod Bolt 35 / 90°
Flywheel
Application N·
·m
12-Sided Stretch Bolt 45 / 90°
Cylinder Head
Application N·
·m
Prechamber Threaded Ring 130
Cylinder Head Cover Bolt 10
Fuel Injsction Pipe Nut 18
Socket Bolt 25
Fuel Filter Pipe Bolt 25
Idle Pulley Bolt 23
Damper Bolt 21
OM600 ENGINE MECHANICAL 1B3-3
Cylinder Head
Application N·
·m
Camshaft Bearing Cap Bolt 25
Camshaft Sprocket Bolt 25 / 90°
Exhaust Pipe Bolt& Nut 25
Chain Tensioner 80
Injection Nozzle 40
Intake Manifold Not 25
Injection Nozzle Pipe Not 18
Oil Dipstick Tube Bolt 10
Screw Plug M18 x 15 50
Cam Support & Shaft

Application N·
·m
Stud Bolt 12
Exhaust Manifold Not 25
CamShaft Bearing Cap Bolt 25
12-Sided Bolt (M11) 25 / 90°
Timing Cover
Application N·
·m
Oil Pan Bolt-Socket Bolt 10
Oil Pan Bolt- M6 10
Oil Pan Bolt- M23 23
Belt Pulley Bolt 32
Guide Pulley Bolt 4
Guide Pulley Bracket Nut 23
Chain Tensioner 80
Tesioning Lever Bolt 23
SPECIAL TOOLS
SPECIAL TOOLS TABLE
603 589 00 09 00 603 589 00 40 00

Serration Wrench Counter Holder
657 589 03 63 00 000 589 77 03 00

Sliding Hammer Box Wrench Insert
601 589 00 66 00 602 589 00 40 00

Counter Sink Engine Lock
667 589 00 23 00 116 589 20 33 00

Height Gauge Sliding Hammer
116 589 03 07 00 115 589 34 63 00

T Type Socket Wrench
601 589 00 10 00
Cylinder Head Bolt 102 601 589 00 25 00
102 589 12 15 00
(f 17) Drift 102 589 00 15 00
(f 34) Drift
617 589 10 21 00 601 589 05 14 00

RI Sensor Assembly Cage
601 589 08 15 00 103 589 00 33 00

Drift Puller
001 589 53 21 00 601 589 03 14 00

Dial Gauge Sleeve
601 589 07 21 00 601 589 03 43 00

Depth Gauge Oil Seal Assembler
667 589 01 21 00 366 589 00 21 05

Fixing Device Extension
363 589 02 21 00 116 589 07 15 00

Dial Gauge Holder Drift
000 589 33 33 00 000 589 04 14 00

Counter Support Tensioning Strap
000 589 25 33 00 102 589 03 40 00

Internal Extractor Magnetic Bar
102 589 05 33 00 601 589 01 59 00

Puller Assembling Board
601 589 02 59 00 667 584 02 63 00

Supporting Bridge Supporting Bar
667 589 00 31 00 104 589 00 37 00

Press Lever Pliers
116 589 06 63 00 601 589 02 43 00

Magnetic Finger Drift
603 589 01 40 00 000 589 10 68 00

Holding Wheel Cylinder Brush
601 589 02 23 00 601 589 05 15 00

Go/No Go Gauge Drift (for Intake)
105 589 03 15 00 601 589 06 15 00

Drift (for Intake) Drift (for Exhaust)
103 589 02 15 00 000 589 10 53 00

Drift (for Exhaust) Reamer (for Exhaust)
346 589 00 63 00 000 589 21 53 00

Super Cooling Box Reamer (for Intake)
001 589 32 21 00 124 589 15 21 00

Dial Gauge Tester
001 589 53 21 00 667 589 02 21 00

Dial Gauge TDC Pulse Generator
000 589 58 43 00 501 589 73 21 00

Chain Assembling Vacuum Pump
Device
201 589 13 21 00 617 589 04 21 00

Vacuum Tester Tester
000 589 14 21 00 601 589 00 08 00

Tester Flange
001 589 65 09 00 116 589 02 34 00

Serration Wrench Thread Bolt
000 589 00 68 00 667 589 04 63 00

Cleaning Set Retaining Plate
601 589 05 21 00 617 589 08 21 00

Looking Screw Position Sensor

ON-VEHICLE SERVICE
ENGINE ASSEMBLY
2. Remove the hood.
3. Remove the skid plate.
Installation Notice
4. Remove the radiator drain cock and drain the coolant.

Notice
Open the coolant reservoir tank cap.
5. Remove the drain plug (1) and seal (2) from the cylinder
block and drain the coolant completely.
6. After draining, replace the seal and reinstall the drain plug.
Installation Notice
7. Disconnect the lower coolant hose from the radiator.

8. Disconnect the upper coolant hose from the radiator.
9. Loosen the bolt and remove the coolant pipe and cooling
fan shroud.
Tightening Torque 3 -7 Nm
10. Remove the hoses (air intake to intercooler, intercooler to

intake duct).
11. Remove the pipes connected to intercooler.

12. Remove the hose(air cleaner to turbocharger) with blow
by hose.
13. Disconnect the air cleaner intake hose and remove the air
cleaner cover and element.
14. Disconnect the coolant hose from the water inlet.
15. Remove the air-conditioner lines from the compressor.

Notice
Evacuate the refrigerant before removal.
16. Remove the power steering pump lines.
Notice
Completely drain the fluid.
17. Disconnect the fuel feed line with prefilter from the feed
pump on injection pump.
18. Vehicle with automatic transmission.

Remove the hydraulic lines (19, 20) from oil cooler (2).
19. Disconnect the engine harness.

20. Disconnect the preheating time relay cable.
21. Remove the fuel lines from the fuel filter and cover the
filter with plug.
22. Disconnect the brake booster hose from vacuum pump.

23. Disconnect the other vacuum lines.
24. Disconnect the ground cable.

25. Disconnect the alternator wires.
26. Disconnect the starter motor wires and remove the starter
motor.
27. Disconnect the preheating time relay sensor plug.
28. Disconnect the coolant temperature sensor plug.
29. Disconnect the accelerator cable from the control linkage.

Installation Notice
30. Loosen the connection of control pressure cable (an arrow)

used in auto transmission.
31. Separate the exhaust pipe flange from the turbo charger.
Installation Notice
32. Loosen the installing bolt of clutch release cylinder and

remove the clutch release cylinder.
Installation Notice
33. Disconnect the exhaust pipe flange from the exhaust

manifold.
Installation Notice
34. Remove the propeller shaft from the transmission.
Installation Notice
Axle 70 ~ 80 Nm
Tightening Torque
T/C 81 ~ 89 Nm
35. Remove the shift control cable.

36. Remove the transmission.
37. Loosen the engine mounting bracket nut.
Installation Notice
38. Remove the engine assembly from the vehicle by using a

hoist or crane.

reverse order.
POLY V-BELT
1 Nut ............................................................. 23Nm 4 Spring

2 Tensioning Lever 5 Tensioning Lever
3 Bolt 6 Poly V-Belt
1. Remove the nut.
2. Push the tensioning lever in direction of arrow with a rod
(F12 ´ 180mm) and pull out the bolt to the rear.
3. Push back the tensioning lever (arrow direction) to release

the spring tension and remove the belt.
4. Install the poly V-belt beginning at the tensioning pulley (7).
7 Tensioning Pulley
8 Crankshaft
9 Alternator
10 Coolant Pump
11 Guide Pulley
12 Power Steering Pump
13 Aircon. Compressor
Lengthe of Belt
With Air Conditioner 2,100 mm

Length (L)
Without Air Conditioner 2,040 mm
TENSIONING DEVICE
1 Bolt ............................................................ 21Nm 10 Tensioning Pulley

2 Damper 11 Socket Bolt ................................................ 29Nm
3 Nut ............................................................. 21Nm 12 Closing Cover
4 Tensioning Lever 13 Washer
5 Guide Rail Pin 14 Tensioning Lever
6 Bolt 15 Fit Bolt ..................................................... 100Nm
7 Poly V-Belt 16 Closing Cover
8 Belt Pulley 17 Spring
9 Bolt ............................................................ 10Nm 18 Bolt ............................................................ 20Nm
1. Remove the nut.
Installation Notice
2. Push the tensioning lever in direction of arrow with a rod
( F12 ´ 180mm ) and push out the bolt to the rear.
3. Push back the tensioning lever to release the spring tension

and remove the belt.
4. Remove the bolt (9) and then remove the belt pulley (8).
5. Remove the bolt (1, 18) and take off the damper (2).
Notice
Pay attention to installation position of the damper.
6. Pull off the tensioning lever (4) from guide rail pin.
7. Remove the spring (17).
Installation Notice
Insert spring (17) with color coding (blue/violet) facing up.
8. Pry off the closing cover (12) and remove the socket bolt
(11) and then remove the tensioning pulley (10).
Installation Notice
9. Pry off the closing cover (16) and remove the fit bolt (15).
10. Remove the tensioning lever (14) and washer (13).
11. Clean thread in the timing case cover and fit bolt.
Installation Notice
Apply Loctite on thread of fit bolt.

reverse order.
POLY V-BELT ALIGNMENT & INSPECTION

Without Air Conditioner
With Air Conditioner

Inspection Procedure
l Mark poly V-belt at a clearly visible point with chalk.
l Rotate the engine and check the belt.
Notice
If one of the following types of damage is found, replace
the belt.
1. Rubber lumps in the base of rips.

3. Pointed rips.
4. Belt cord visible in the base of rips.

7. Belt detached from the base of rip.
8. Splits across the rips.

9. Sections of rip torn out.
10. Splits across several rips.
11. Splits across the back.

PRECHAMBER
Preceding Work : Removal of glow plug
Removal of fuel injection nozzle
1 Threaded Ring ........................................ 130 Nm 3 Cylinder Head

2 Prechamber
Tools Required
603 589 00 09 00 Serration Wrench

1. Using the serration wrench (4), remove the threaded ring
(1).
Serration Wrench 603 589 00 09 00
2. Install the sliding hammer into the prechamber.
3. Remove the perchamber (2).

Notice
After removing the prechamber, cover over the bores with
clean rag.
4. Inspect the prechamber.

Notice
If the prechamber seats in the cylinder head are leaking or
if the prechambers are replaced, the sealing surfaces in
the cylinder head must be remachined.
Assembly Procedure
Notice
In case the prechambers are reused, inspect the
prechambers thoroughly, if the ball pin by heat and fire is
broken, it can not be used.
1. Clean the sealing surface of the prechamber.

2. Insert the prechamber into the cylinder head at the same
time aligning the cam on the collar of the prechambers with
the slots in the cylinder head.
Notice
If the spacer rings are fitted to the prechambers, the spacer
rings should be replaced with rings of the same thickness.
Thickness of Spacer Ring 0.3, 0.6, 1.0 mm
3. Coat the threaded ring with oil and assemble the ring by
using the serration wrench.
MILLING OF PRECHAMBER SEALING SURFACE
1 Drift 4 Counter Sink (Special Tool - 601 589 00 66)

2 Sleeve 5 Cylinder Head
3 Milling Cutter
Tools Required
601 589 00 66 00 Counter Sink
667 589 00 23 00 Height Gauge
Milling of the Prechamber Sealing Surface

Notice
The prechamber sealing surface may only be remachined
once with the cylinder head fitted. It is essential to adhere
to the specified projection ‘C’ of the prechamber of 7.6 -
8.1mm.
This ensures that the required clearance exists between
prechamber and piston crown with the piston in TDC. For
this reason, spacer rings should be inserted on remachined
sealing surfaces.
Tightening Torque 0.3, 0.6, 1.0 mm

If a spacer ring is already fitted, or a marking is made on the
cylinder head, the cylinder head must be removed and size
‘C’ measured if further remachining is necessary on a
prechamber sealing surface.
1. Remove the injection nozzle.
2. Remove the prechamber.
3. Cover the prechamber bore to avoid any chips dropping
into the combustion chamber.
4. Remove the protective sleeve from the countersink and
rotate the countersink into the prechamber bore to be
machined as far as the stop.
Counter Sink 601 589 00 66 00
5. Maintain size ‘X’ from the top edge of mandrel to the top
edge of the sleeve with the gauge.
Height Gauge 667 589 00 23 00
6. Measure the ‘X’ by using a vernier caliper.
7. Mount the turning tool onto the countersink tool and rotate
to the right approx. 5 revolutions by applying slight pressure.
8. Remeasure size ‘X’ and compare it with the first
measurement and determine the thickness of spacer ring.
Ex Size before machining 25.7 mm

Size after machining 25.5 mm
The spacer ring should be selected so that it is at least
0.1mm and not more than 0.3mm thicker than the
measured on the sealing surface. In this example, the
necessary thickness of spacer ring should be within
0.3 ~ 0.5mm and the thickness of spacer ring to be
installed is 0.3mm.
9. Remove the countersink tool and clean the chips.
Notice
If the sealing surface is not completely flat, remachine the
sealing surface.
10. emove rag from the prechamber bore and crank the engine
with starter motor to threw out any chips which may have
got into the combustion chamber.
11. Insert the proper spacer ring into the prechamber sealing
surface.
12. Punch a mark on the cylinder head above the prechamber
sealing surface which has been machined.
13. Install the prechambers.
Notice
If the cylinder head is removed, the projection ‘C’ is
measured in place of size ‘X’ and the appropriate size of
spacer ring selected.
Normal Projection (c) 7.6 - 8.1mm

TDC (TDC SENSOR BRACKET) SETTING

Preceding Work : Removal of No.1 cylinder prechamber
1 Measuring Device
2 Dial Gauge
3 Cylinder Head
4 Piston ................................................ Set at TDC
Tools Service
001 589 32 21 00 Dial Gauge
601 589 07 21 00 Deqth Gauge
667 589 01 21 00 Fixing Device
Notice
l The TDC sensor bracket must be adjusted in case of
followings.
l When replacing the TDC sensor bracket.
l When replacing the crankshaft, the hub or the vibration
damper.
l When replacing or installing the timing case cover.
l After engine overhauling.
* If the cylinder head is removed, the measuring pin of the

dial gauge can be positioned on the piston crown.
This is done by placing the magnetic dial holder on the
mating surface of the crankcase.
Setting (with cylinder head installed)
1. Remove the prechamber of No. 1 cylinder.
2. Position the piston of No.1 cylinder at BTDC 10.
3. Install the measuring device into the prechamber bore and

position the dial gauge with a preload of 5mm.
Dial Gauge 001 589 53 21 00
Depth Gauge 601 589 07 21 00
4. Slowly rotate the crankshaft in the direction of engine rotation

until the large pointer on the dial gauge stops (TDC position).
Notice
The position of TDC is when the large pointer on the dial
gauge is stopped before moving back.
5. remove the reinstall the measuring device and position the
dial gauge scale at ‘0’.
6. Slowly rotate the crankshaft in the direction of engine rotation
until the dial gauge has moved back (counterclockwise) by
3.65mm.
7. Insert fixing device into the sensor bracket.

Notice
The pin on the vibration damper must engage into the slot
of the fixing device.
Fixing Device 667 589 01 21 00
8. If the pin does not engage, adjust the setting of the sensor
bracket by removing and tightening of the sensor bracket
bolts.
Notice
The timing mark on the damper must be positioned at ATDC
20.
CYLINDER HEAD
1 Fuel Injection Pipe ..................................... 18Nm 21 Camshaft Drive Sprocket ....................... Replace
2 Cylinder Head 22 Washer
3 Gasket ................................................... Replace 23 Bolt(12-Sided) .................................. 25Nm + 90°
4 Bolt ............................................................ 25Nm 24 Sliding Rail
5 Washer 25 Sliding Rail Pin
6 Clamp 26 Sliding Rail Pin
7 Heater Feed Pipe 27 Chain Tensioner ....................................... 80 Nm
8 Bolt 28 Gasket ................................................... Replace
9 Washer 29 Cooling Fan .............................................. Check
10 Bolt 30 Hexagon Socket Bolt ................................. 45 Nm
11 Nozzle Washer ....................................... Replace 31 Tensioning Lever
12 Fuel Injection Nozzle ............................ 35-40 Nm 32 Bolt ........................................................... 25 Nm
13 Hexagon Socket Bolt ................................. 25 Nm 33 Bolt
14 Washer 34 Nut ............................................................ 23 Nm
15 Bolt ........................................................... 25 Nm 35 Fuel Filter
16 Cylinder Head Bolt .............................. See Table 36 Turbo Charger
17 Cylinder Head Cover 37 Intake Duct
18 Bolt ........................................................... 10 Nm 38 Gasket ................................................... Replace
19 Gasket 39 Intake Manifold
20 Camshaft
Tightening Torque
Cylinder Bolts (12-sided socket head) stage1 10 Nm

(Engine cold) stage2 35 Nm
stage3 180°
M8 Cylinder Head Bolts 25 Nm
Tools Required
102 589 03 40 00 Magnetic Bar
116 589 02 34 00 Threaded Pin
116 589 03 07 00 T Type Socket Wrench
601 589 00 10 00 Cylinder Head Bolt Wrench
602 589 00 40 00 Engine Lock
603 589 00 40 00 Counter Holder
Tightening Sequence for Cylinder Head Bolts

OM 662LA Engine
OM 661LA Engine
Notice
The cylinder head may only be removed when the engine
has cooled down. The cylinder head is removed together
with the exhaust manifold. As the cylinder head bolts
undergo a permanent tightening. They require to be
replaced if they exceed the maximum lengthes indicated
in the table.
Thread Dia. Length(L) When New Max. Length(L)
M10 80mm 82mm
M10 102mm 104mm
M10 115mm 117mm
The twelve-sided socket head bolts are tightened with each
stages of torque and torque angle.
It is not necessary to retighten the cylinder head bolts at
the 1000~1500km inspection or after 1000~1500km of
repairs.
Disassembly Procedure
1. Completely drain the coolant from the radiator and cylinder
block.
3. Hold the fan with counter holder and remove the bolt and
then remove the cooling fan.
Notice
Keep the fan in vertical position.
Counter Holder 603 589 00 40 00
4. Remove the bracket oil dipstick tube.
5. Remove the nut.

6. Remove the nut on the tensioning lever and insert the
rod(F12 ´ 180mm). By pushing the rod to the arrow direction,
pull back the bolt.
7. Push the tensioning lever to the opposite direction to release

the spring tension and remove the poly V-belt.
8. Remove the air cleaner cover and element and then
remove the air cleaner housing.
9. Remove the oil return hose and plug.
Notice
Cover them to prevent chips from coming into.
10. Unscrew the EGR pipe mounting bolts onto the exhaust
manifold.
11. Remove the duct bracket from the cylinder head.
12. Unscrew the intake duct mounting bolts onto the intake
manifold.
13. Separate the connecting rod from the control lever.

14. Pull out the accelerator control linkage.
15. Remove the fuel injection line(1) from the fuel injection
nozzle(12).
Box Wrench Inset 000 589 77 03 00
16. Remove the fuel injection line from the fuel injection pump.
17. Remove the bracket mounting bolts and then remove the
fuel injection line(1).
18. Disconnect the booster hose connected to intake manifold.
19. Remove the intake manifold and gasket.
20. Remove the cylinder head cover and gasket with the blow-
by gas hose.
21. Disconnect the glow plug cables.

22. Remove the cable channel.
23. Disconnect the cables from the glow plug sensor and
coolant temperature sensor.
24. Remove the heater pipe bracket from the oil filter.
25. Pry off the clamp and push the heater feed pipe forward
and then pull out the pipe.
26. Disconnect the fuel lines from the fuel filter.
27. Disconnect the fuel lines from the injection pump.
28. Remove the fuel filter(35).
29. Remove the fuel injection nozzle(12) and nozzle

washer(11).
Socket Wrench Insert 001 589 65 09 00

30. Rotate the crankshaft and set the no.1 cylinder at TDC.
Notice
Do not rotate the crankshaft to the opposite direction of
engine revolution.
31. Place alignment marks on the camshaft gear and timing

chain.
32. Ensure that the camshaft and the bearing cap marking
are aligned.
33. Remove the starter motor and install the engine lock onto
the flywheel ring gear.
Engine Lock 602 589 00 40 00

34. Remove the turbocharger.
35. Remove the exhaust manifold and gasket.
36. Remove the chain tensioner and seal.
37. Remove the bolt and separate the drive sprocket(21).

Notice
During removal, be careful not to drop the sprocket and
chain into the timing case.
Carefully pull off the chain and then pull out the sprocket.
38. Remove the camshaft bearing cap bolts according to the
numerical sequence.
Notice
Remove the No.1 bolts first and then remove the No. 2
bolts. Do not remove the bolts at a time completely but
remove them step by step evenly or camshaft can be
seriously damaged.
OM662LA
OM661LA
39. Remove the bearing caps and then pull out the
camshaft(20) upward.
Notice
Be careful not to miss the locking washer.
40. Remove the locking washer.

Notice
Check the locking washer and replace if necessary.
41. Remove the bolt(32).
42. Separate the spring and pull out the tensioning lever(31).
43. Pry off the closing cover. Remove the bolt and then remove
the idle pulley.
44. Using the sliding hammer(36) and the threaded pin(37),

pull out the sliding rail pins(25, 26) and remove the sliding
rail(24).

Threaded Pin 116 589 02 34 00
45. Remove the vacuum line from the vacuum pump.
46. Disconnect the vacuum pipe from thermo valve.
47. Remove the socket bolts(13) of the chain box.
T Type Socket Wrench 116 589 03 07 00

Magnetic Bar 102 589 03 40 00
48. Remove the cylinder head bolts in numerical se-quence.
Cylinder Head Bolt Wrench 601 589 00 10 00
OM 662LA
OM 661LA
49. Remove the cylinder head(2) and gasket(3).

Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.

Notice
Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts.

Notice
If the max. length is exceeded, replace the bolts.
Thread Dia. Length(L) Max. Limit(L)

when new
M10 80mm 82mm
M10 102mm 104mm
M10 115mm 117mm
4. Coat the head contact surface of bolts and thread with oil OM662LA
and insert them as shown.
- Cylinder head bolts arrangement

Bore
1 ........................................... M10 × 80
2 ........................................... M10 × 102
3 ........................................... M10 × 115
4 ........................................... M 8 × 50
5 ........................................... M 8 × 80
5. Tighten the cylinder head bolts to specified torque and
torque angle.
Stage 1 15 Nm
Stage 2 35 Nm
Torque angle 90°
Wait for 10 minutes
Torque angle 90°
OM 661LA OM 662LA
6. Install the socket bolts in the chain box.
7. Connect the vacuum pipe to the thermo valve.

8. Connect the vacuum lines to the vacuum pump.
9. Install the fuel filter and connect the pipe.

Notice
Be careful not to be confused the connections and hoses.
10. Connect the fuel pipe to the injection pump.
11. Install the sliding rail(24) and insert the sliding rail pins(25,
26).
Notice
Apply sealing compound on the each collar of the sliding
rail pins.

Threaded Pin 116 589 02 34 00
12. Install the idle pulley and fit the closing cover.
13. Insert the tensioning lever(31) and install the spring.
14. Install the damper.

Notice
Insert the tensioning lever bolts onto the mounting hole.
15. Insert the locking washer.

16. Inspect the valve tappet and check that the tappet moves
smoothly.
17. Coat the camshaft with oil and install the camshaft on the
cylinder head to be TDC mark(arrow) upward.
18. Measure the axial end play of the camshaft.
End Play 0.06 - 0.21mm
Notice
If out of standard, adjust it with the proper thickness of
locking washer.
19. Install the bearing caps on the camshaft according to the

number on the caps.
20. Tighten the bearing cap bolts according to the numerical

sequence.
Notice
Tighten the No. 1 bolts(light arrow) first and then tighten
the No. 2 bolts(dark arrow) stage by stage.
OM662LA
OM661LA
21. Position the camshaft on marking and install the camshaft
sprocket.
Notice
Align the alignment marks on the chain and sprocket.
22. Check the TDC position of the crankshaft.
23. Install the camshaft sprocket bolt.

Notice
Measure the max. length ‘L’ and replace the bolt if it exceeds
53.6mm.
24. Install the exhaust manifold and gasket.
25. Install the turbocharger.
26. Install the exhaust pipe onto the turbocharger.

27. Replace the seal and then install the chain tensioner.
28. Remove the engine lock.
29. Insert the nozzle washer into the hole to face round part
downward.
31. Connect the fuel hose.

32. Install the cable channel and connect the cables to glow
plugs.
33. Replace the gasket and install the cylinder head cover.
34. Install the blow-by hose.
35. Connect the wires to the coolant temperature sensor and

the glow plug sensor.
36. Replace the intake manifold gasket.
37. Install the intake manifold.

38. Replace the O-ring of heater feed pipe and install it to the
cylinder head.
Notice
For installation, clean the hole.
39. Install the bracket of heater feed pipe to the oil filter.
40. Install the fuel pipe and the accelerator control linkage.
41. Connect the fuel lines to the injection nozzles and to the
injection pump.
42. Install the poly V-belt.
Notice
Be careful not to contaminate the belt.
43. By inserting a rod into the tensioning lever upper hole and
pulling the rod, install the bolt and then tighten the nut.
44. Install the oil dipstick tube bracket.

45. Hold the cooling fan with the counter holder and tighten
the bolt.
TIMING CASE COVER

Preceding Work : Removal of the cooling fan
Rmoval of the V-belt tensioning device
Removal of the vibration damper and hub
Removal of the alternator
1 Bolt ............................................................ 10Nm 13 Bolt ............................................................ 32Nm

2 Cylinder Head Cover 14 Timing Case Cover
3 Gasket ................................................... Replace 15 Bolt ............................................................ 23Nm
4 Socket Bolt ................................................ 25Nm 16 Alternator Bracket
5 Fuel Filter 17 Bolt ............................................................ 45Nm
6 Square Nut 18 Bolt ............................................................ 25Nm
7 Oil Pan 19 Bolt ............................................................ 10Nm
8 Socket Bolt ................................................ 10Nm 20 Closing Cover
9 Bolt .................................................... M6 : 10Nm 21 Socket Bolt ................................................ 23Nm
M8 : 23Nm 22 Guide Pulley
10 Power Steering Pump 23 Bolt .............................................................. 9Nm
11 Bolt 24 Guide Pulley Bracket
12 Belt Pulley 25 Nut ............................................................. 23Nm
Tools Required
116 589 03 07 00 Socket Wrench
Removal Procedure
1. Remove the fan clutch and cooling fan belt pulley.
2. Drain the engine oil completely.
3. Remove the oil dipstick tube bracket bolts.
4. Remove the crankshaft pulley.
5. Loosen the bolt (1) and then remove the cylinder head cover
(2) and gasket.
6. Remove the vacuum pump.
7. Detach the closing cover (20). Remove the bolts(21) and

then remove the guide pulley (22).
8. Remove the guide pulley bracket (24).

9. Disconnect the pipes of power steering pump and remove
the belt pulley.
Notice
Be careful not to lose the key.
10. Remove the nut and pull out the bolt and then remove the
power steering pump.
11. Remove the alternator bracket (16).
12. Remove the fuel filter.

13. Remove the camshaft.
14. Remove the socket bolts(4) in the chain box.
Socket Wrench 115 589 03 07 00
15. Remove the injection pump.

Notice
See the ‘Removal of fuel injection pump’.
16. Remove the oil pan bolts (8, 9) in the area of the timing
case cover (14).
17. Slightly loosen the remaining oil pan bolts.
18. Remove the timing case cover (19) bolts and then remove
the timing case cover (14).
Notice
Be careful not to damage the cylinder head gasket or oil
pan gasket.
1. Thoroughly clean the sealing surface and apply sealant.
2. Install the timing case cover.

Notice
Bolts arrangement
1.M6 x 60
2.M6 x 70
3.M6 x 40
3. Tighten the socket bolts in the chain box.

4. Tighten the oil pan bolts.
Socket bolt 10 Nm
Tightening Torque M6 bolt 10 Nm
M8 bolt 23 Nm
5. Install the flange, vibration damper and crankshaft belt
pulley.
Notice
Replace front radial seal if necessary.
6. Install the alternator bracket.
Front 25 Nm
Tightening Torque
Side 25 Nm
7. Install the alternator
Upper - 25 Nm
Tightening Torque
Low - 25 Nm
8. Install the cylinder head cover.

9. Tighten the injection pump mounting bolts.
10. Install the fuel filter.

11. Install the vacuum pump.

12. Install the power steering pump.
13. Install the power steering pump pulley.
14. Install the guide pulley bracket.
15. Install the guide pulley (22) and fit the closing cover (20).
16. Replace the gasket (3) and install the cylinder head cover
(2).
17. Install the cooling fan belt pulley and fan clutch.
18. Install the belt tensioning device and then install the belt.
19. Install the cooling fan.
20. Fill the engine oil and check oil leaks by running the engine.
CRANKSHAFT END COVER

Preceding Work : Removal of flywheel and driven plate.
1 Crankshaft Flange 4 Radial Seal ............................................ Replace

2 End Cover .............................. Clean, Loctite 573 5 Dowel Sleeve
3 Bolt ......................................... 10Nm, Loctite 573 6 Bolt ......................................... 10Nm, Loctite 573
Tools Required
601 589 03 43 00 Oil Seal Assmbler
Removal Procedure
1. Remove the bolts (3, 6) from end cover, By pulling out the
lugs (arrow), remove the cover.
Notice
2. Remove the radial seal (4) with care not to damage the
sealing surface.
1. Thoroughly clean the sealing surface of end cover and apply
Loctite 573.
2. Clean the groove of radial seal.
3. Apply Loctite 573 on the bolts and install the end cover.
Notice
4. Install the inner oil seal assembler to the crankshaft flange.
Oil Seal Assembler 601 589 03 43 00

5. Coat a little oil on the sealing lip of new radial seal and
contacting surface.
Notice
Don’t use grease.
6. Insert the new radial seal (4) onto the oil seal assembler
(7).
Notice
The sealing lip of the repair radial seal is offset to the inside
by 3mm to ensure that it does not run in any groove which
the standard radial seal may have left on the crankshaft
flange.
A Standard Radial Seal
B Repair Radial Seal
7. Install the outer oil seal assembler on he seal and by

tightening the bolts, press the radial seal into the end cover
as far as the stop.
Notice
The seal must be positioned exactly at right angles in the
end cover to ensure that it provides a proper seal.
Oil Seal Assembler 601 589 03 43 00

VIBRATION DAMPER AND HUB

Removal of poly V-belt
1 Bolt ............................................................ 10Nm 6 Bolt ................................................ 200Nm + 90°

2 Cooling Fan Belt Pulley 7 Washer
3 Socket Bolt ................................................ 23Nm 8 Straight Pin
4 Crankshaft Belt Pulley 9 Hub
5 Vibration Damper 10 Oil Pan
Sectional View
3 Socket Bolt 9 Hub

4 Crankshaft Belt Pulley 11 Radial Seal
5 Vibration Damper 12 Timing Gear Case Cover
6 Bolt 13 Key
7 Washer 14 Crankshaft Sprocket
8 Straight Pin 16 Crankshaft
Notice
The mounting position of vibration damper is fixed by straight
pin (8).
Tools Required
602 589 00 40 00 Engine Lock
103 589 00 30 00 Puller
Removal Procedure
1. Remove the starter motor and install the engine lock into
the wheel ring gear.
Engine Lock 602 589 00 40 00
2. Remove the poly V-belt.

3. Remove the cooling fan.
Notice
Keep the fan in vertical position.
4. Remove the cooling fan belt pulley (2).

5. Place alignment marks (arrow) on the vibration damper (5)
and crankshaft belt pulley (4).
6. Remove the timing sensor bracket.

Notice
Remove if necessary.
7. Remove the socket bolts (3) and then remove the belt
pulley (4) and vibration damper (5).
8. Remove the washer and bolt.
9. Remove the hub by using a puller.
Puller 103 589 00 33 00

10. Replace the radial seal.
1. Install the hub.
Notice
Exactly align the woodruff key and the groove of hub (arrow).
2. Install the washer (7) and tighten the bolt (6).

Washer (new) : 1 EA 200 Nm + 90°
3. Install the vibration damper.

Notice
Exactly align and insert onto the straight pin.
4. Install the belt pulley.

Notice
Align the alignment marks.
5. Install the timing sensor bracket.
Notice
See the ‘TDC setting’.
6. Install the cooling fan pulley.

7. Install the cooling fan.
8. Install the fan belt.

1 Radial Seal 3 Woodruff Key

2 Timing Case Cover
Tools Required
601 589 03 14 00 Sleeve
Notice
The sealing lip of the repair radial seal is offset to the inside
by 2mm to ensure that is does not run in any groove which
the standard radial seal may have left on the crankshaft
flange.
A Standard Radial Seal
B Repair Radial Seal
1. Pull out the radial seal (1) and be careful not to damage the
sealing surface of timing case cover.
2. Thoroughly clean the mounting bore of the radial seal.
3. Coat a little oil on the sealing lip of new radial (1) and contact
surface.
Notice
Don’t use grease.
4. Install the radial seal (1) by using a sleeve (4).
Notice
Align the groove of sleeve and woodruff key(arrow).
Sleeve 601 589 03 14

CRANKSHAFT BALL BEARING
1 Spacer 3 Ball Bearing

2 Cover ......................................... Replace 4 Bolt ....................................... 45Nm + 90°
Notice
Manual transmission only.
Tools Required
000 589 33 33 00 Counter Support
000 589 25 33 00 Internal Extractor

1. Remove the manual transmission.
2. Using a puller, pull out the locking ring and ball bearing
together.
Counter Support 000 589 33 33 00

Internal Extractor 000 589 25 33 00
3. Apply Loctite 241 on the new ball bearing and then insert
the ball bearing to be stopped at the spacer ring by using a
proper mandrel.
CRANKSHAFT
Preceding Work : Removal of the end cover
Removal of the piston
Removal of the crankshaft sprocket
3 Crankshaft Main Bearing Shells (Upper) 7 Thrust Bearings (Lower)

4 Trust Bearings (Upper) 8 Crankshaft Bearing Cap
5 Crankshaft 9 Crankshaft Bearing Cap (Fit Bearing)
6 Crankshaft Main Bearing Shells (Lower) 10 12-sided Stretch Bolts ....................... 55Nm + 90°
Tools Required
001 589 53 21 00 Dial Gauge
363 589 02 21 00 Dial Gauge Holder
366 589 00 21 05 Extension
Thrust Washer and Bearing Arrangement
OM662LA Engine
3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings

4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.
OM661LA Engine
3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings

4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing)
5 Crankshaft
6 Crankshaft Main Bearing Shells (Lower)
7 Thrust Bearings (Lower)
Notice
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.
Crankshaft Standard and Repair Sizes
mm
Crankshaft bearing Thrust bearing Thrust bearing
journal diameter journal width journal diameter
24.500 - 24.533
Standard size 50.950 - 57.965 47.950 - 47.965
24.600 - 24.633
Repair size 1 57.500 - 57.715 24.700 - 24.733 47.700 - 47.715
Repair size 2 57.450 - 57.465 24.900 - 24.933 47.450 - 47.650
Repair size 3 57.200 - 57.215 25.000 - 25.033 47.200 - 47.215
Repair size 4 56.950 - 56.965 - 46.950 - 46.965
Bearing Clearances
mm
Thrust bearing Crankshaft bearing
Radial clearances New 0.027 - 0.051 0.026 - 0.068
Limit Max. 0.070 Max. 0.080
Axial clearances New 0.100 - 0.254 -
Limit Max. 0.300 -
Matching Fit Bearing Journal Width to Thrust Bearings

mm
Fit bearing journal width Thrust bearings thickness
24.500 - 24.533 2.15
24.600 - 24.633 2.20
24.700 - 24.733 2.25
24.900 - 24.933 2.35
25.000 - 25.033 2.40
Notice
l Measure crankshaft axial clearance and adjust with proper thrust Bearing.
l The same thickness of washer must be installed on both sides of the fit bearing.
Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft
Marking of basic bearing bore in lower Color code of relevant crankshaft

parting surface bearing shell
1 punch mark or blue Blue or white-blue
2 punch marks or yellow Yellow or white-yellow
3 punch marks or red Red or white-red
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft
Color code of relevant crankshaft

Marking of bearing journals on crank webs bearing shell
Blue or white-blue Blue or white-blue
Yellow or white-blue Yellow or white-yellow
Red or white-blue Red or white-red
1. Remove the bearing cab bolt.
2. Remove the bearing caps (8).
Notice
The crankshaft bearing caps are marked with stamped
numbers. Remove the bearing cap from the vibration
damper side.
3. Remove the crankshaft bearing caps (9) and lower thrust

bearings (7).
4. Remove the lower thrust bearings (6) from the bearing cap
(9).
5. Remove the crankshaft (5).
6. Remove the upper thrust bearings(4).

7. Remove the upper bearing shells (3) from crankcase.
8. Thoroughly clean the oil gallery.
9. Select a proper new bearing shells with reference to table.
10. Coat the new bearing shells with oil and insert into the
crankcase and into the crankshaft bearing caps.
Notice
Do not mix up upper and lower crankshaft bearing shells.
11. Install the bearing caps according to marking and tighten
the 12-sided stretch bolts.
Notice
No. 1 is vibration damper side.
12. Measure crankshaft bearing diameters (E).
Extension 366 589 00 21 05
13. Measure at 3 points (A, B and C) and if the average value

of B and C is less than A’s value, the average value of B
and C is the mean value and if more than A’s value, A’s
value is the mean value.
14. Measure crankshaft bearing journal diameter (F).

Notice
When measured in A and B, the runout should not exceed
0.010mm.
15. Measure radial clearance of crankshaft bearing (G).
Clearance ‘G’ 0.027 - 0.051mm
Notice
If ‘G’ is out of standard, replace the bearing shells and
adjust the radial clearance of crankshaft bearing.
Example) Measured value ‘E’ = 57.700mm
Measured value ‘F’ = 57.659mm
Clearance ‘G’ = 0.041mm
16. Remove the crankshaft bearing cap.
17. Measure width of thrust bearing journal (H) and adjust with
proper thrust bearings (see table).
Notice
The same thickness of thrust washers should be installed
on both sides of the thrust bearing.
18. Coat the upper thrust bearing (4) with oil and insert into
the crankcase so that the oil grooves are facing the crank
webs (arrow).
19. Coat the lower thrust bearing (7) with oil and insert into the
crankshaft bearing cap so that the oil grooves are facing
the crank webs (arrow).
Notice
The retaining lugs should be positioned in the grooves
(arrow).
Notice
If the max. length of bolts(L) exceed 63.8mm, replace them.
19. Coat the new crankshaft with engine oil and place it on the
crankcase.
20. Install the crankshaft bearing caps according to marking
and tighten the bolts.
Notice
Install from No. 1 cap.
22. Rotate the crankshaft with hand and check whether it

rotates smoothly.
23. Measure crankshaft bearing axial clearance.
Clearance 0.100 - 0.245mm
Notice
If the clearance is out of standard, adjust the axial clearance
of crankshaft bearing by replacing the thrust washers.
Dial Gauge 001 589 53 21 00

Dial Gauge Holder 363 589 02 21 00
Notice
The same thickness of thrust washers should be installed
on both sides of the thrust bearing.
24. Insert the new connecting rod bearing shells into the
connecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
26. Measure connecting rod bearing journal diameter (K).

Notice
Refer to measurement of the crankshaft bearing journal
diameter.
27. Measure the radial clearance (L) of the connecting rod
bearing.
Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’ 0.026 - 0.068mm

Notice
If the clearance is out of standard, adjust the radial
clearance of connecting rod bearing by replacing the
connecting rod bearing shells.
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotates
smoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve.
- clean the oil pump and oil filter housing carefully and
replace the hose if necessary.
Notice
After assembling the engine, check the camshaft timing,
adjust the start of fuel injection and check the TDC sensor
bracket setting.
32. Fill oil and run the engine and then check the oil pressure
and oil level.
Notice
Install the original oil filter element and then change the
engine oil and oil filter element after 1,000 - 1,500km.
FLYWHEEL
Preceding Work : Removal of the transmission
Removal of the clutch
1 Oil Pan 4 12-Sided Stretch Bolt ............ Check, 45Nm + 90°

2 Straight Pin 5 Drive Plate (Automatic Transmission)
3 Flywheel 6 Flywheel (Automatic Transmission)
l Manual transmission flywheel
OM662LA OM661LA
l Automatic transmission flywheel

Tools Required
602 589 00 40 00 Engine Lock

1. Install the engine lock.
Engine Lock 602 589 02 40 00
2. Remove the 12-sided stretch bolts (4).

Installation Notice
Notice
If the length ‘L’ of bolts exceeds 22.5mm, replace the bolts.
3. Remove the flywheel (3), if equipped with manual

transmission.
Installation Notice
Correctly align the position of dowel pin (2).
4. Remove the flywheel (6) and driven plate (5), if equipped
with automatic transmission.
Installation Notice
Correctly align the position of dowel pin (2).
reverse order.
MACHINING OF FLYWHEEL
1 Flywheel
Machining of Flywheel OM662LA OM662LA
Notice
Flywheels which have scorch marks, scoring or cracks in
the clutch surface should be machined by grinding or
precision-turning. If the scores or cracks are severe than
permissible specifications, replace the flywheel.
Distance ‘a’ 19.3 - 19.5 mm

Distance ‘b’ New 16.6 mm
Repair up to 15.6 mm
Max. axial runout 0.05 mm
l When machining the clutch surface ‘A’, the mounting

surface (B) for the clutch pressure plate should also be
machined in accordance with ‘A’ to keep the distance ‘a’.
l Do not machine under ‘b’ value.
l When machining, fix the flywheel exactly not to exceed the
standard runout.
FLYWHEEL RING GEAR

Preceding Work : Removal of flywheel
1 Ring Gear 3 Centering Collar Diameter

2 Flywheel
Tools Required
001 589 53 21 00 Dial Gauge
1. Drill a hole into the ring gear (1) (arrow) and snap
with a chisel.
2. Thoroughly clean the collar surfaces of ring gear.
3. Measure diameter (a) of centering collar.

Diameter ‘a’ 275 + 0.5mm
Notice
If out of standard, replace the flywheel.
4. Heat up the new ring gear up to 220°C by using a

heating device.
Notice
Use temperature measuring chalk.
5. Install the new ring gear (1) onto the flywheel by using a
drift.
6. Measure axial runout of ring gear (1) on a surface plate.
Limit Max. 0.4mm
Notice
For correct measurement, put the flywheel on the flat
measuring board.
Dial Gauge 001 589 53 21 00

HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK
1 Cylinder Head Cover 4 Valve Tappet

2 Bolt ............................................................ 10Nm 5 Cylinder Head
3 Gasket ................................................... Replace
Checking
Notice
The noise which continues short time during short travel
(frequent starting of the engine) or engine starting after a
long time storage is normal operating conditions. So, it does
not need to be repaired. Determine the malfunctions in valve
clearance compensation device with noise through following
tests. If defective, replace as respectively.
1. Run the engine at more than 3000rpm for approx. 4 minutes.
2. Stop the engine. After 5minutes, check the engine oil level
and adjust if necessary.
3. Remove the cylinder head cover.
4. Check the valve tappets at TDC position of each cylinders.
5. Using a drift, lightly press the valve tappet and measure
clearance between the cam and valve tappet.
Notice
If the clearance exceeds 0.4mm, replace the valve tappet.
6. If a valve tappet moves down too far in comparison to the
others, replace the valve tappet.
7. Rotate the engine and check the remaining valve tappets.
Notice
l Unnecessary rotation of the engine will damage the valve
tappets.
l Do not rotate the engine by using the camshaft sprocket
bolt or to the opposite direction of the engine rotation.
VALVE TAPPETS
1 Valve Tappet 4 Seal ....................................................... Replace

2 Cylinder Head 5 Screw Plug
3 Oil Gallery
Tools Required
102 589 03 40 00 Magnetic Bar
1. Pull out the valve tappet (1).
Magnetic Bar 102 589 03 40 00
2. Remove the plug (5) and blow compressed air into the oil
gallery (3). At this time, check that the outlet bores(arrow)
at the seat of the valve tappet are clear.
3. Replace the seal (4) and tighten the plug (5).
4. Insert the new valve tappet.
Notice
Coat the valve tappet with oil.
VALVE SPRINGS CHECK

1 Valve Spring 2 Spring Scale
Service Data
At preloaded
Outer diameter Wire diameter Free length
Length Tension (new) Limit
33.1mm 4.20mm 50.0mm 27mm 680 - 740N 612N
VALVE SPRINGS (CYLINDER HEAD REMOVED)

Cylinder Head Removed
1 Valve Tappet 6 Stud Bolt .................................................... 12Nm

2 Valve Cotters 7 Washer
3 Spring Retainer 8 Nut .............................................. Replace, 25Nm
4 Valve Spring ........... Check, replace if necessary 9 Exhaust Manifold
5 Cylinder Head
Tools Required
102 589 03 40 00 Magnetic Bar
601 589 01 59 00 Assembling Board
601 589 02 59 00 Supporting Bridge
667 589 00 31 00 Press Lever

1. Remove the nuts (8) uniformly and then remove the washer
(7), exhaust manifold (9) and gasket.
Installation Notice
Check the stud bolt (6) for damage and replace if necessary.
Tighten Torque 12 Nm
Replace the gasket and tighten the nuts (8).
Tighten Torque 25 Nm
2. Install the assembling board (11) to the cylinder head with 4

cylinder head blots (10).
Assembling Board 601 589 01 59 00
3. Pull out the valve tappet (1) with magnetic bar (12).
Notice
Place the valve tappets upside down (open end upward).
Magnetic Bar 102 589 03 40 00
4. Install the supporting bridge (13) on the cylinder head (5).
Supporting Bridge 601 589 02 59 00

5. Using the press lever (14), press the spring retainer
downward and remove the valve cotters (2) with magnetic
finger (15).
Notice
Be careful not to damage guide bore of the valve tappet.
Press Lever 667 589 00 31 00

6. Remove the spring retainer (3) and spring (4).

Installation Notice
Install the valve spring with the color coding (arrow) facing
down.
7. Check the valve spring and replace if necessary.
reverse order.
VALVE SPRINGS (CYLINDER HEAD INSTALLED)

1 Valve Tappet 4 Valve Spring .......... Check, replace if necessary

2 Valve Cotters 5 Timing Chain
3 Spring Retainer 6 Cylinder Head
Notice
Remove the valve springs only when the piston is at TDC.
Tools Required
102 589 03 40 00 Magnetic Bar
603 589 01 40 00 Holding Wheel
667 589 00 31 00 Press Lever
1. Remove the valve tappet (1) with magentic lifter.
Notice
Place the valve tappets upside down (open end upward)
Magentic Liter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain of camshaft
sprocket piston.
Holding Wheel 603 589 01 40 00
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8).
5. Using the press lever (9), press the spring retainer(3)

downward and remove the valve cotters (2) with magnetic
finger (10).
Notice
Press Lever 667 589 00 31 00

6. Remove the spring retainer(3) and spring (4).
7. Check the valve spring and replace if necessary.
8. Insert valve spring (4) with the color coding (arrow) facing
down and insert valve spring Retainer(3).
9. By press the spring retainer(3) with press lever (90), install

the valve cotters with magnetic finger (10).
Press Lever 667 589 00 31 00

10. Remove the supporting bar.

11. Remove the holding wheel (7) from the timing chain (5).
13. Coat the valve tappet with oil and install it.
Magnetic Bar 102 589 03 40 00

VALVE STEM SEALS

Preceding Work : Removal of camshaft.
1 Valve Tappet 4 Valve Spring ........... Check, replace if necessary

2 Valve Cotters 5 Valve Stem Seal
3 Spring Retainer 6 Valve
Notice
Remove the valve stem seals when the piston is positioned at TDC.
Tools Required
667 589 00 31 00 Press Lever
104 589 00 37 00 Pliers
102 589 03 40 00 Magnetic Lifter
603 589 01 40 00 Holding Wheel
601 589 02 43 00 Drift
A : Intake valve stem seal B : Exhaust valve stem seal
Intake valve stem seal Exhaust valve stem seal

Chamfer Offset All round
Inner diameter ‘d’ 7.3mm 8.2mm
Color Brown Green
Wire ring Black Yellow
1. Remove the valve tappet (1) with magnetic lifter.
Notice
Place the valve tappets upside down (open end upward).
Magnetic Lifter 102 589 03 40 00
2. Install the holding wheel (7) into the timing chain (11).
3. Position the piston of relevant cylinder at TDC.
4. Install the supporting bar (8).
5. Using press lever (9), press the spring retainer(3) downward

and remove the valve collets with magnetic finger (10).
Press Lever 667 589 00 31 00

6. Remove the spring retainer(3) and valve spring (4).
7. Remove the valve stem seal (5).
Pliers 104 589 00 37 00
8. Insert the cap (12) onto the valve (6) and install the new
valve stem seal (5) and then remover the cap.
Drift 601 589 02 43 00
9. By pressing the spring seat with press lever (9), install the
valve cotters(2) with magnetic finger (10).
Notice
Press Lever 667 589 00 31 00

CHECK AND REPLACEMENT OF VALVE GUIDES

Removal of valve spring
Removal of valve
1 Cylinder Head 3 Valve Seat Ring

2 Valve Guide a Basic Bore Diameter
Service Data
Item Outer Diameter ‘D’ Color Code Basic Bore Overlap Valve Guide Length ‘L’
Diameter ‘a’ ‘D’ - ‘a’ Inner Diameter ‘A’
Repair size 1 14.251 Red 14.200 - 14.211 0.029 8.000
Intake 39.5
Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051 - 8.030
Repair size 1 14.240 - 14.251 Red 14.200 - 14.211 0.029 9.000
Exhaust 37.7
Repair size 2 14.440 - 14.451 White 14.400 - 14.411 - 0.051 - 9.050
Notice
Measure center (arrow) of the valve guide and if the inner
diameter ‘A’ exceeds standard value, replace the guide.
Tools Required
000 589 10 53 00 Reamer (for Exhaust)
000 589 10 68 00 Cylinder Brush
000 589 21 53 00 Reamer (for Intake)
102 589 00 23 00 GO / NO GO Gauge (for Intake)
103 589 02 15 00 Drift (for Exhaust)
103 589 03 15 00 Drift (for Intake)
117 589 03 25 00 GO / NO GO Gauge (for Exhaust)
346 589 00 63 00 Super Cooling Box
601 589 02 23 00 GO/NO GO Gauge
601 589 05 15 00 Drift (for Intake)
601 589 06 15 00 Drift (for Exhaust)
Matching Valve Seat - Broaching Tools - Guide Sleeves

Valve Seat Broaching Tool No. Guide Sleeve Tool No. Guide Sleeve Side
Intake 115 589 00 53 00 102 589 00 63 00 B
Exhaust (14.2mm) 102 589 08 63 00 B
Intake 115 589 01 53 00 A
601 589 15 63 00
Exhaust (14.4mm) B
Checking
1. Thoroughly clean the valve guide bore using a cylinder
brush.
Cylinder Brush 000 589 10 68 00
2. Insert the GO/NO GO gauge into the valve guide bore. If

the NO GO side is inserted fully, replace the valve guide
(Intake 8mm, Exhaust 9mm).
GO/NO GO Gauge 601 589 02 23 00
1. Drive out the valve guide (2) by using a drift (5).
Notice
The valve guide must be driven out upward of the cylinder
head.
Drift (for Intake) 103 589 03 15 00
Drift (for Exhaust) 103 589 02 15 00
2. Thoroughly clean the basic bore by using a cylinder brush.
Cylinder Brush 000 589 10 68 00
3. Check the basic bore in cylinder head for scoring marks

and ream to next repair size if necessary.
4. Reaming basic bore in cylinder head (repair size).
- Thoroughly remove carbon deposits in cylinder head.
Notice
Particularly remove the insides of the valve seat rings.
- Remove the elevation (arrow) of intake valve seat rings.
- Select correct broaching tool and guide sleeve (refer to

the table).
Notice
Before broaching work, the broaching tool must be cleared
of swarf with a stiff plastic brush.
- Lubricate the basic bore, guide sleeve and broaching tool

with petroleum.
- Push broaching tool (6) in broaching direction (arrow) into
the guide sleeve (7) far enough so that the first cut of the
broaching tool is positioned in the basic bore when guide
sleeve is fitted onto the valve seat ring (3).
6. Broaching tool
7. Guide sleeve
See the ‘standard data’
- Center the guide sleeve (7) in the valve seat ring (3) by
turning.
- Knock through the broaching tool (6) with a plastic hammer
(approx. 25g). and aluminum drift.
5. Heat the cylinder head (1) in a wear tank to approx. 80°C.
6. Cool down the new valve guide (2) with liquid nitrogen.
Notice
Do not touch the cooled valve guide by hand.
Super Cooling box 346 589 00 63 00
7. Drive in new valve guide with drift (8) until the wire ring makes
contact.
Notice
The valve guide must be driven in from the cylinder head
cover.
Drift (for Intake) 601 589 05 15 00
Drift (for Exhaust) 601 589 06 15 00
8. Check the valve guide bore with GO / NO GO gauge (9).

The GO side (marked ‘0’) should just still drop. If the GO
side cannot be inserted, the bore of valve guide should be
reamed.
Notice
Perform the check only on cooled down cylinder head.
GO / NO GO Gauge (for Intake) 102 589 00 23 00

GO / NO GO Gauge (for Exhaust) 117 589 03 23 00
9. If necessary, ream the valve guide bore evenly.
Notice
Never turn the reamer against the direction of rotation.
Reamer (for Exhaust) 000 589 10 53 00

Reamer (for Intake) 000 589 21 53 00
VALVE SEAT RINGS

Preceding Work : Removal of valve
Checking of valve guide, replace if necessary
Removal of prechamber
1 Cylinder Head D Valve Seat Ring Outer Diameter

2 Valve Seat Ring D1 Valve Seat Ring Inner Diameter
3 Valve Guide D2 Basic Bore Diameter
A Height (Cylinder Head Upper / Lower Surface) H Height of Valve Seat Ring
B Height (cylinder Head Cover Surface - Seat of
Valve Seat Ring)
Service Data
Item Intake Exhaust
D2 40.000 - 40.016mm 37.000 - 37.016mm
D 40.084 - 40.100mm 37.084 - 37.100mm
D1 33.400 - 33.600mm 30.400 - 30.600mm
H 6.955 - 7.045mm 6.955 - 7.045mm
Overlap U=D-D2 0.068 - 0.100mm 0.068 - 0.100mm
B 133.4mm 133.4mm
A 142.5mm 142.5mm
Commercial Tools
Cylinder Head Clamping Device Hunger
D-8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning Tool Hunger
D-8000 München 70
Type VDS 1A
Order No. 236 03 308
Ring Seat Turning Tool Hunger
D-8000 München 70
Type RDS 1
Order No. 219 00 100
Pneumatic Removal / Installation Device Hunger
(Drift : 8mm, 9mm, 14mm) D-8000 München 70
Type PVM 1
Tensioning Head Hunger
D-8000 München 70
Order No. 250 15 250
Cutting Tool for Recessing Grooves Hunger
D-8000 München 70
Order No. 217 93 601
Test Set for Valves Hunger
D-8000 München 70
Order No. 216 69 210
Internal Dial Gauge (Range : 25 - 60mm) Mahr
D-7300 Esslingen
Order No. 844
External Micrometer (Range : 25 - 60mm) Mahr
D-7300 Esslingen
Order No. 40 S
Electrically Heated Water Tank Otto Dürr
D-7123 Sachsenherm - Ochsenbach
Removal Procedure
1. Measure dimension ‘A’.
Limit 142.5mm
2. Clamp the cylinder head with clamping device.
3. Cut groove into the valve seat ring so that dimension ‘C’ is
approx. 2mm and dimension ‘E’ is approx. 6mm.
4. Remove the cylinder head from the clamping device and

place it onto wooden blocks.
5. Remove the valve guide (3).
Drift (Intake) 8mm

Drift (Exhaust) 9mm
6. Insert the tensioning head (4) and extracted wedges(arrow)

by turning the bolt (5).
Notice
Carefully tighten the bolt (5) otherwise the valve seat ring in
the cylinder head will be excessively tensioned.
7. Lock the bolt (5) with nut (6).
8. Turn over the cylinder head.
9. Remove the tensioning head (4) and valve seat ring (2)
with drift (14mm) and removal tool.
10. Clean the basic bore of valve seat ring.
11. Measure the basic bore diameter (D2) and outer diameter
(D) of the new valve seat ring (standard size).
12. Calculate the overlap value ‘U’ (D - D2).
Overlap Value ‘U’ 0.068 - 0.100mm
Example) Measured value D = 37.100mm
Measured value D2 = 37.010mm
Overlap value ‘U’ = 0.090mm

If overlap value ‘U’ is out of standard, machine
the basic bore for the valve seat ring.
13. Clamp the cylinder head with clamping device.

14. Machining basic bore for valve seat ring (repair size).
Notice
Maintain minimum value of ‘B’.
- Machine the basic bore.
Limit
Intake 40.516mm
Max. D2
Exhaust 37.516mm
Min. B 133.4mm
- Measure machined basic bore and outer diameter ‘D’

of valve seat ring (repair size).
- Measure the overlap ‘U’
Overlap ‘U’ (D - D2) 0.068 - 0.100 mm
Example) Measured value D = 37.600 mm
Measured value D2 = 37.480 mm
Overlap U = 0.120 mm
The basic diameter D2 must be machined by
0.020mm in order to get the required overlap
value.
15. Hang the cylinder head (1) to the lifting device and heat in
a water tank to approx. 80°C.
16. Cool down new valve seat ring (2) into the cooling box with
liquid nitrogen.
Notice
Do not touch the cooled valve seat rings with hand.
Super Cooling Box 345 589 00 63 00
17. Drive in new valve seat ring (2) with a proper wooden drift.
18. Install the valve guide (3) with a proper drift and assembling
tool.
Notice
The valve guide must be driven in from the cylinder head
cover.
Drift (Intake) 8mm

Drift (Exhaust) 9mm
19. Machine the valve seats.

CHECK AND MACHINING OF VALVES

Preceding Works : Removal of cylinder head
Removal of the vale spring
Removal of the valve
I Valve Length Y Half Camshaft Basic Bore Diameter

W Camshaft Cam Basic Diameter Z Distance (Cylinder Head Cover Parting Surface -
X Distance (Camshaft Basic Bore - Valve Stem) Valve Stem)
Intake Valve Exhaust Valve
Item Intake Valve Exhaust Valve

Valve Disc Diameter ‘d’ 37.90 - 38.10 mm 34.90 - 35.10 mm
Valve Disc Height ‘h’ 1.7 mm 1.7 mm
Setting Angle “a” or Machining the Valve 45° 45°
Valve Stem Diameter ‘d1’ 7.955 - 7.970 mm 9.945 - 8.960 mm
Valve Length ‘I’ Standard 106.20 - 106.60 mm 106.20 - 106.60 mm
Repair 105.30 - 105.70 105.30 - 105.70 mm
Max. Permis Sible Runout at Valve Stem and Valve Seat 0.03 mm 0.03 mm
Matching Valves
Camshaft Cam Basic Dia. Camshaft Cam Basic Dia. Valve to be Used
W = 38.0 ± 0.2mm W = 36.6 ± 0.2mm
Use machined valve,
if needed
Size (x) 19.5 - 20.3mm 19.5 - 20.1mm
new repair valve
I = 105.5 ± 0.2mm
Size (x) 20.4 - 21.4mm 20.2 - 21.2mm Reuse valve
Use standard size
Size (x) 21.4 - 21.97mm 21.2 - 21.97mm valve
I = 106.4 ± 0.2mm
Tools Required
001 589 32 21 00 Dial Gauge
Commercial Tool
Valve corn grinding machine
Checking and Machining
1. Clean the valves and do visual check.
Valves with wobbled valve disc, with worn or scored valve
stem should be replaced.
2. Measure valve disc height ‘h’.
Intake 1.7 ± 0.15 mm
Service data
Exhaust 1.7 ± 0.15 mm
3. Machine the valve.

Notice
Pay attention to setting angle ‘a’.
4. Measure radial runout between valve stem and valve seat.
Limit Max. 0.03mm
Dial Gauge 001 589 32 21 00

5. Clean the vales, valve seats and valve guides.
6. Coat the valve stem with oil and insert it into valve guide.
7. Insert the valves (1) into the valve guides according to

marking.
8. Measure amount by which the valve arrears ‘a’.
Arrears ‘a’ 0.1 - 0.7 mm
Notice
If out of standard, replace the valve seat ring.
9. Measure camshaft cam basic diameter (w).
38 ± 0.2 mm
Diameter ‘w’
or 37.6 ± 0.2 mm
10. Measure distance ‘z’ (cylinder head cover parting surface

- valve stem).
11. The distance ‘x’ (camshaft basic bore - valve stem).
‘x’ = ‘z’ - ‘y’.
Determine the valve to use according to this measurement
(See ‘matching valves’)
Example) Measured value ‘w’ = 38.2 mm

Measured value ‘z’ = 36.5 mm
Value ‘y’ = 15.5 mm
‘x’ = 36.5 - 15.5 = 21.0mm

In this case according to ‘Matching valves’ table, the
installed valve may be used.
MACHINING OF VALVE SEAT

Preceding Work : Removal of prechamber
Removal and inspection of valve, replace if necessary
Inspection of valve guide, replace if necessary
1 Valve a Valve Seat Angle

2 Valve Seat Ring b Valve Seat Free Angle
3 Cylinder Head
4 Valve Guide
Service Data
Item Intake Exhaust
Valve Arrears ‘a’ 0.1 - 0.7 mm 0.1 - 0.7 mm
Valve Seat Width ‘b’ 1.2 - 1.7 mm 1.5 - 2.0 mm
Valve Seat Angle ‘a’ 45° 45°
Valve Seat Free Angle ‘b’ 65° 65°
Permissible Radial Runout 0.03 mm 0.03 mm
Valve Length ‘I’ Standard 106.20 - 106.60 mm 106.20 - 106.60 mm
Repair 105.30 - 105.70 mm 105.30 - 105.70 mm
Matching Valves
Camshaft cam basic dia. Camshaft cam basic dia. Valve to be used
w = 38.0 ± 0.2 mm w = 37.6 ± 0.2 mm
Use machined valve,
if needed
Size (x) 19.5 - 20.3mm 19.5 - 20.1mm
use pair valve
1 = 105.5 ± 0.2mm
Size (x) 20.4 - 21.4mm 20.2 - 21.2mm Reuse valve
Use standard size
Size (x) 21.4 - 21.97mm 21.2 - 21.97mm valve
I = 106.4 ± 0.2mm
Commercial Tools
Cylinder Head Clamping Devie Hunger
D-8000 München 70
Type Ventilknecht K2000
Order No. 221 00 100
Valve Seat Turning Tool Hunger
D-8000 München 70
Type VDS 1A
Order No. 236 03 308
Test Sat for Valves Hunger
D-8000 München 70
Order No. 217 93 601
Machining Procedure
Valve machining is required :
- When the valve is leaking.
- When replacing the valve.
- When replacing the valve guide.
- When replacing the valve seat or valve seat ring.
1. Machine the valve seat (a=45°).
2. Measure valve seat width ‘b’.
Valve seat Intake 1.2 - 1.7 mm

width ‘b’ Exhaust 1.5 - 2.0 mm
3. If the specification is exceeded, the valve seat width has to

be corrected at the lower free angle of ‘b’=65°.
4. Measure radial runout.

Runout Max. 0.03mm
5. Insert the valve (1) into the valve guide according to marking
and measure amount by which the valve arrears ‘a’.
Arrears ‘a’ 0.1 - 0.7mm
6. Measure camshaft cam basic circle diameter (w).

38 ± 0.2mm
Diameter ‘w’
or 37.6 ± 0.2mm
7. Measure distance ‘z’ (cylinder head cover parting surface

- valve stem).
I Length of Valve y Half Camshaft Basic Bore Diameter

w Camshaft Cam Basic Circle Diameter z Distance (Cylinder head cover parting surface - .
x Distance (Camshaft basic bore - valve stem) valve stem)
8. Measure ‘x’ (Camshaft basic bore - valve stem).

‘x’ = ‘z’ - ‘y’
9. Determine the valve to be used.
(See ‘Matching valves’)
Example) Measured value ‘w’ = 38.2 mm
Measured value ‘z’ = 36.5 mm
Value ‘y’ = 15.5 mm
‘x’ = 36.5 - 15.5 = 21.0 mm
In the case of a camshaft cam basic circle diameter
‘w’ = 38.2mm and a distance ‘x’ = 21.0mm, the installed
valve may be used.
CAMSHAFT TIMING TEST

1 Cylinder Head Cover 4 Valve Tappet

3 Gasket ................................................... Replace
Timing
Intake valve Exhaust valve
Condition of camshaft
Open Close Open Close
New ATDC 11.33° ABDC 17° BBDC 28° BTDC 15.25°
After approx. 20,000km ATDC 12° ABDC 18° BBDC 27° BTDC 14°
«
At 2mm of valve lifting stroke.
Tools Required
001 589 53 21 00 Dial Gauge
366 589 00 21 05 Extension
Measurement Procedure
1. Remove the cylinder head cover.
2. Rotate the engine in the direction of engine rotation until
the intake valve of NO. 1 cylinder is completely closed. The
cam lobe faces up (arrow).
Notice
Do not rotate the engine at the bolt of the crankshaft
sprocket. Do not rotate the engine in the opposite direction
of engine rotation. If do, this will cause serious measuring
errors.
3. Install the dial gauge holder and dial gauge (7) with the
extension (8) to the cylinder head and position the tracer
pin (9) onto the valve tappet (intake valve of cylinder NO.1)
with a preload of min. 3mm.
Notice
The tracer pin should be positioned exactly vertical.
Dial gauge Holder 363 589 02 21 00
Dial Gauge 001 589 53 21 00
Extension 366 589 00 21 05
4. Set the dial gauge to ‘0’.

5. Rotate the engine further in direction of rotation until the
dial gauge has moved back by 2mm (valve lift) to 1mm.
6. Check the timing.
New ATDC 11.33°
After approx. 20,000km ATDC 12°
Notice
If timing is out standard, the camshaft should be checked
for wear and the timing chain for stretch. If a difference of
more than 4° exists, the timing chain should be replaced.
CAMSHAFT

2 Washer 9 Oil Pan
3 Camshaft Bearing Cap 10 Camshaft Sprocket
4 Camshaft 11 Washer
5 Dowel Pin 12 12-Sided Bolt (M11) ............. Check, 25Nm + 90°
6 Locking Washer 13 Gasket ................................................... Replace
7 Timing Chain 14 Chain Tensioner ........................................ 80Nm
Tools Required
602 589 00 40 00 Engine Lock
Removal Procedure
1. Rotate the crankshaft and position the piston of no.1 cylinder
at TDC.
Notice
Do not rotate the crankshaft in the opposite direction of
engine rotation.
In this position, the markings of the camshaft/camshaft

bearing cap (arrow) must be aligned.
2. Place alignment marks on the camshaft sprocket and timing

chain.
3. Remove the starter motor and install the engine lock.
Engine Lock 602 589 00 40 00

4. Remove the bolt and then remove the camshaft sprocket.
Notice
During removal, be careful not to drop the sprocket with
chain. Remove the chain carefully and then pull out the
sprocket.
6. Remove the camshaft bearing cap bolts according to the

removal order.
Notice
Remove the camshaft bearing cap bolts of 1(dark arrow)
first and then remove the bolts of 2 (light arrow) one
revolution in stages until the counter-pressure is released.
In order to avoid damaging the camshaft, it is essential to
adhere to the removal order for the camshaft bearing caps.
OM 662LA
OM 661LA
7. Remove the camshaft bearing cap.
8. Pull off the camshaft.
Notice
Be careful not to miss front locking washer.
9. Pull out the locking washer.

Notice
Check the condition of locking washer and replace if
necessary.
1. Insert the locking washer.
2. Check the valve tappet and ensure that tappet moves
smoothly.
3. Coat the camshaft with oil and install the camshaft onto the
cylinder head so that the TDC marking (arrow) is positioned
upward vertically.
4. Install the camshaft bearing caps according to markings(1,

2, 3 etc.).
5. Tighten the camshaft bearing cap bolts acccording to
installation order.
Notice
Tighten the No. 1 bolts (light arrow) by one revolution in
stages first and then tighten the No.2 bolts (dark arrow).
OM 662LA
OM 661LA
6. Install the camshaft sprocket to be aligned the markings of

the camshaft / camshaft bearing cap (arrow).
Notice
Align the alignment marks on the timing chain and sprocket.
7. Tighten the camshaft sprocket bolt.

Tightening Torque 25Nm + 90°
Notice
If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm,
replace it.
Notice
Replace the seal.
Before installation, by pumping in the oil approx. 10 times,
fill the oil.
10. Check the TDC marking of OT on the crankshaft.

CHAIN TENSIONER
1 Chain Tensioner ........................................ 80Nm 2 Seal ....................................................... Replace

Notice
Always install the chain tensioner to be filled with oil.
Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up.
Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill
Faulty chain tensioners should be replaced completely.
3 Screw Plug 11 Valve Disc

4 Aluminum Gasket 12 O-Ring
5 Ball 13 Snap Ring
6 Ball Guide 14 Compression Spring
7 Compression Spring 15 Filler
8 Compression Spring
9 Housing A Feed Bore from Cylinder Head
10 Thrust Pin B To Oil Pan
TIMING CHAIN
Removal of chain tensioner
Removal of cooling fan
Removal of cylinder head cover
1 Chain Link
2 Timing Chain
3 Camshaft Sprocket
4 Outer Plate
Tools Required
000 589 58 43 00 Chain Assembling Device
1. Cover over the chain box with cleaning rag and grind off
both chain pins (arrow) at a chain link (1) of the timing chain.
2. Remove the outer plate (4) and chain link (1).

Notice
Ensure that the ends of the timing chain do not drop into
the chain box.
3. Loosen the chain tension with approx. 4 turns.

4. Connect the new timing chain (arrow) with chain link (1) to
the old timing chain (2).
5. By rotating the crankshaft in the of engine rotation, pull out

the old timing chain with installing the new timing chain.
6. Remove the old timing chain and hold the ends of the new
timing chain to camshaft sprocket (3) with wire (arrow).
7. Insert the new chain link (1) to connect the chain.
8. Insert the new outer plate (4) into the fitting tool (8) and
then the outer plate will be held by a magnet.
Chain Assembling Device 000 589 58 43 00
9. Place the fitting tool (8) onto the chain link and press the
outer plate on as far as the stop.
10. Switch over the die (9) of the fitting tool (8).
11. Place the fitting tool (8) onto the chain link and rivet the
chain pins one by one.
12. Check the riveting of chain pins and re-rivet if necessary.

13. Remove the wire.
14. Position the no.1 cylinder at TDC.
In this position, the marking on camshaft / camshaft bearing

cap (arrow) must also be aligned. If the markings are not
aligned, the timing chain must be re-set and the injection
pump timing has to be set.
TENSIONING RAIL
Removal of timing case cover
1 Tensioning Rail 2 Bearing Pin
Notice
The plastic coating of the tensioning rail can not be replaced.

Removal of poly V-belt
Removal of chain tensioner
1 Cylinder Head Cover 9 Bearing Pin ........................... Sealing Compound

2 Bolt ............................................................ 10Nm 10 Guide Rail
3 Gasket ................................................... Replace 11 Bearing Pin
4 Camshaft Sprocket 12 Guide Pulley
5 Washer 13 Socket Bolt ................................................ 23Nm
6 12-Sided Bolt (M11) ............ Inspect, 25Nm + 90° 14 Closing Cover
7 Tensioning Lever 15 Spring
8 Bolt ............................................................ 23Nm 16 Timing Chain
Tools Required
116 589 20 33 00 Threaded Pin
Removal Procedure
1. Removal the cylinder head cover.
2. Pull off the tensioning lever (7) and remove from the spring
(15).
3. Pry off the closing cover (14) and remove the bolt (13) and
then remove the guide pulley (12).
4. Place alignment marks (arrow) on the timing chain (16) and

camshaft sprocket (4).
5. Remove the camshaft sprocket.

6. Pull out the bearing pins (9, 11) with sliding hammer and
remove the guide rail 10.

Threaded Pin 116 589 02 34 00
1. Apply collar of both bearing pins with sealing compound.
2. Position the guide rail and insert the bearing pins.
3. Install the camshaft sprocket.
Notice
If the max. length ‘L’ of the 12-sided bolt exceeds 53.6mm,
replace it.
4. Position the no. 1 cylinder at the TDC of OT.

In this position, the marking on the camshaft / camshaft
bearing cap (arrow) must also be aligned.
5. Install the guide pulley (12).

6. Attach the tensioning lever (7) to the spring (15) and install.
TIMING CASE COVER GUIDE RAIL

1 Bearing Pin 5 Crankshaft

2 Bearing Pin 6 Spring
3 Guide Rail 7 Bushing
4 Oil Pump Chain 8 Tensioning Lever
Removal Procedure
1. Pull out the tensioning lever (8) together with the spring (6)
and guide rail (3) far enough until the tensioning lever has
moved passed the oil pump chain (4) and is resting against
the crankshaft (5)
2. Pull the tensioning lever (8) off the bearing pin (2) and
carefully remove the spring (6). Remove the tensioning lever
(8) together with the spring (6) and bushing (7).
3. Remove the guide rail (3).
1. Install the guide rail (3). Attach the spring (6) to the guide
rail and to the tensioning lever (8).
Notice
Ensure that the spring is correctly located in the guide rail
(arrow).
2. Push the guide rail, spring, bushing and tensioning lever
together onto the bearing pin (1, 2).
CRANKSHAFT SPROCKET
Removal of timing case cover
1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90° 11 Bolt ............................................................ 25Nm
2 Washer 12 Crankshaft Sprocket
3 Camshaft Sprocket 13 Crankshaft
4 Timing Chain 15 Key
5 Bearing Pin 16 Guide Rail
6 Bearing Pin 17 Spring
7 Oil Pump 18 Bushing
8 Oil Pump Sprocket 19 Tensioning Lever
9 Oil Pump Chain
10 Washer
Special Tools
116 589 07 15 00 Drift
102 589 05 33 00 Puller
Removal Procedure
1. Pull out the tensioning lever (19) together with the spring
(17) and guide rail (16) far enough until the tensioning lever
has passed the oil pump chain (9) and is resting against
the crankshaft (13).
2. Pull out tensioning lever (19), spring (17) and bushing (18)
from the bearing pin (6).
3. Pull out the guide rail (16).
4. Remove the bolt(11) and then remove the washer (10), oil
pump chin (9) and sprocket (8).
crankshaft sprocket (12).
6. Remove the woodruff key(15).


9. Remove the bolt (1) and then remove the washer (2) and
10. Remove the crankshaft sprocket (12) by using a puller

(20).
Puller 102 589 05 33 00

1. Put the same alignment mark on the new crankshaft
sprocket as in the old sprocket.
Notice
Check the timing chain, camshaft sprocket, injection pump
timing sprocket, oil pump chain and oil pump sprocket for
wear and replace if necessary.
2. Install the new crankshaft sprocket (12) by using a drift (21).

Notice
Align the groove of sprocket and woodruff key (arrow)
exactly.
Drift 116 589 07 15 00
3. Fit the timing chain (4) on the crankshaft sprocket (12).

Notice
Align the alignment marks (arrow) on the chain and sprocket.
4. Install the camshaft sprocket (3).

Notice
Pay attention on the alignment marks and dowel pin (arrow).
Notice
If the max. length ‘L’ of the stretch bolt exceeds 53.6mm,
replace it.
5. Fit the oil pump chain (9) on the crankshaft sprocket (12)
and insert the oil pump sprocket (8) into the oil pump chain
and then install it on the oil pump.
Notice
The curved side of the oil pump sprocket should face the
oil pump.
6. Insert the woodruff key (15).
7. Install the guide rail (16). Attach the spring (17) to guide rail
and to tensioning lever together onto the bearing pins (5,6).
Notice
Ensure that the spring is correctly located in the guide rail
(arrow).
PISTON
Preceding Work : Removal of the cylinder head
Removal of the oil pump
1 Oil Ring 8 Connecting Rod

2 2nd Ring 9 Connecting Rod Upper Bearing Shell
3 Top Ring 10 Connecting Rod Lower Bearing Shell
4 Snap Ring .............................................. Replace 11 Connecting Rod Bearing Cap
5 Piston Pin 12 Connecting Rod Bolt ......................... 35Nm + 90°
6 Piston 13 Crankcase
7 Connecting Rod Bushing .......................... Check 14 Cylinder Bore
Notice
There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing
the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there
would be a unbalancing of engine.
Service Data
Piston clearance Max. 0.12 mm
Piston crown protrusion in TDC position 0.735 - 0.965 mm
Connecting rod bushing diameter 26.012 - 26.018 mm
Connecting Rod Bolt Dimensions

Thread M9 x 1
Stretch shaft(C) diameter (new) 7.4-0.1 mm
Minimum stretch shaft diameter (C) 7.1 mm
Length(L)(new) 52-0.3 mm
Tools Required
000 589 04 14 00 Tensioning Strap
001 589 53 21 00 Dial Gauge
Removal Procedure
1. Remove combustion residues from the cylinder bores.
2. Remove the connecting rod bolts (12) and then remove
the connecting rod bearing caps(11).
3. Remove the connecting rod bearing shells (9, 10).

Notice
Be careful not mix the bearing caps and shells each other.
4. Remove the piston (6) and connecting rod (8).
6. Separate the piston and connecting rod.
1. Fit the piston onto the connecting rod so that the arrow
(15) and the locking slot (16) are facing in direction of the
vehicle.
2. Coat the piston pin (15) with engine oil and insert it by hand.
Notice
Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (arrow).
4. Check the piston rings (1, 2, 3) and replace them if
necessary.
5. Install and arrange the piston rings to be evenly 120° from

each ends gap.
6. Coat the cylinder bore, connecting rod bearing journal,
connecting rod bearing shell and piston with oil.
7. Compress the piston rings with a tensioning strap (7).
Tensioning Strap 000 589 04 14 00
8. Insert the piston assembly into the cylinder with a wooden

stick (18).
Notice
The arrow on the piston crown must point toward the front
of vehicle.
9. Insert the connecting rod bearing shells (9, 10).

Notice
Be careful of the difference in upper and lower bearing
shells and not to be changed.
10. Position the connecting rod bearings caps.
Notice
Position so that the retaining lugs are on the same side of
the connecting rod bearing(arrow).
11. Measure stretch shaft diameter (C) of the connecting rod

bolts.
Limit ‘C’ 7.1mm

12. Coat the bolts (12) with oil and then tighten the bolts.
Tightening Torque 40Nm + 90°
13. Rotate the crankshaft and check axial clearance between

the connecting rod and crankshaft.
14. Measure clearance between the piston crown and cylinder
Standard Max. 0.12mm
15. Position the piston at TDC and measure the distance

between the piston crown and the crankcase surface.
Standard Max. 0.965 mm
Notice
Measure at points marked.
Dial Gauge 001 589 00 53 21

OIL FILTER
1 Nut ............................................................ 25 Nm 6 Bolt (M8) .................................................... 10Nm

2 Oil Filter ..................................................... Cover 7 Oil Pressure Switch
3 O-Ring ................................................... Replace 8 Gasket
4 Oil Filter ............... Element Replace If necessary 9 Bolt ........................................................... 25 Nm
5 Oil Filter Housing
1. Remove the oil filter cover and then drain the oil.
2. Remove the oil pressure switch line.
3. Remove the oil filter housing.

reverse order.
OIL PAN
OM662LA OM661LA
1 Gasket ................................................... Replace 6 Lower Oil Pan

2 Upper Oil Pan 7 Combination Bolt ...................................... 25 Nm
3 Combination Bolt ...................................... 10 Nm 8 Drain Plug ................................................. 25 Nm
4 Combination Bolt ...................................... 10 Nm 9 Washer Seal .......................................... Replace
5 Gasket ................................................... Replace 10 Oil Pan
*Remove and install as numerical sequence.

Notice
Replace the washer seal with new one.
Oil Circulation
Oil Filter
a From Oil Pump

b To Main Oil Gallery
c To Oil Pan
OIL SPRAY NOZZLE
1 Fitting Sleeve 3 Combination Bolt ..................................... 10 Nm

2 Oil Spray Nozzle A Oil Duct
1. Remove oil pan or crankshaft.
2. Loose the bolt and then remove the nozzle.
OIL PUMP
1 Oil Pump 5 Screw Plug ................................................ 50 Nm

2 Piston 6 Combination Bolt ...................................... 25 Nm
3 Pressure Spring 7 Oil Strainer
4 Guide Pin 8 Bracket
1. Remove the oil pan.
2. Unscrew the mounting bolt of spracket.
3. Unscrew the oil strainer bracket bolt.
4. Remove the oil pump.
5. Unscrew the screw plug and remove the relief valve.

reverse order.
UNIT REPAIR
CYLINDER HEAD PRESSURE LEAKAGE TEST
Preceding Work : Removal of the cylinder head
Removal of the exhaust manifold
Removal of the valve
1 Feed Pipe
2 Bolt
3 Return Connection
4 Gasket ................................................................ Replace
5 Coolant Gallery ................................................... Sealing
6 Pressure Measuring Plate .................................. Completely tight to the cylinder head
7 Cylinder Head .....................................................
Immerse with pressure measuring plate into warm water of approx. 60°C and pressurize with compressed
airof 2 bar.
Notice
If air bubbles are seen, replace the cylinderhead.
Tools Required
115 589 34 63 00 Pressure Measuring Plate
601 589 00 25 00 Suspension Device
FACING CYLINDER HEAD MATING SURFACE

Preceding Work : Removal of prechamber
Cylinder head pressure leakage test
1 Valve B Longitudinal Direction

2 Cylinder Head C Transverse Direction
3 Prechamber a Valve Arrears
A Height of Cylinder Head b Prechamber Protrusion
Service Data
Height ‘A’ 142.9 - 143.1mm
(cylinder head surface - cylinder head cover surface)
Minimum height after machining 142.5mm
Permissible unevenness of parting surface In longitudinal direction 0.08mm
In transverse direction 0.0mm
Permissible variation of parallelism (longitud. Direction) Max. 0.1mm
Peak-to-valley height 0.0017mm
Valve arrears ‘a’ Intake valve 0.1 - 0.7mm
Exhaust valve 0.1 - 0.7mm
Prechamber protrusion 7.6 - 8.1mm
Measurement Procedure
1. Measure height ‘A’.
Limit 142.5 mm
Notice
If the height is less than 142.5mm, replace the cylinder head.
2. Insert the valve (1) and measure valve arrears ‘a’.

Valve Arrears ‘a’ 0.1 - 0.7 mm
Notice
If out of standard, machine the valve seat.
3. Install the prechamber and measure protrusion ‘C’.

Protrusion ‘C’ 7.6 - 8.1mm
4. Assemble the engine and check the valve timing.
REPLACEMENT OF CRANKCASE CORE PLUG
Left Right
Core plug ....................................................... f34mm Core plug ....................................................... f34mm

OM661LA - 2EA OM661LA - 2EA
Left Right
Core plug ....................................................... f17mm Core plug ....................................................... f34mm

Tools Required
102 589 00 15 00 Drift
102 589 12 15 00 Drift
1. Completely drain the coolant.
2. Remove any parts which impede access.
(Example : transmission, injection pump)
3. Place the screwdriver to the deepdrawn edge of the core
plug and pull forward and then rotate 90°.
4. Pull out the core plug with pliers.
5. Thoroughly clean the sealing surface and apply Loctite 241.

6. Install the new core plug by using a drift.
Drift 102 589 00 15 00 (F34)

Drift 102 589 12 15 00 (F17)
7. Install the removed parts and fill the coolant.

Notice
The adhesive must be allowed to harden for about 45
minutes before filling of coolant.
FACING CRANKCASE CONTACTING SURFACE
1 Crankcase B Longitudinal Direction

2 Crankcase Contacting Surface C Transverse Direction
H Chamfer Height
Y Height (crankcase upper surface - crankcase b Chamfer Angle
lower surface)
Service Data
Height ‘Y’ Min. 299.62 mm
Permissible unevenness of contacting surface In longitudinal direction (B) 0.06 mm
In transverse direction (C) 0.06 mm
Permissible roughness upper contacting surface 0.0006 - 0.0016 mm
Permissible variation of parallelism of crankcase upper 0.05 mm
surface to lower surface in longitudinal direction
Piston protrusion at TDC to crankcase upper surface Max. 0.965 mm
Min. 0.735 mm
OIL GALLERY STEEL BALL

Removal of the coolant pump housing
Removal of the flywheel and driven plate
1 Steel Ball ................................................. f15mm 2 Screw Plug ............................... Loctite 241,50Nm
Notice
The screw plug (2) has to be installed as a repair solution if the steel ball (1) is leaking.
3 Steel Ball ................................................. f17mm 5 Screw Plug ................................................. 50Nm

4 Seal
Notice
The seal (4) and screw plug (5) have to be installed as a repair solution if the steel ball (3) is leaking.
Tools Required
601 589 08 15 00 Drift
1. Remove the timing case cover.
2. By inserting a round bar (6) approx. 0.7m from the back to
the front side through the oil gallery, knock out the steel
balls (1,3).
Notice
Be careful not to damage the bores of the steel balls.
6 Shop-made tool
3. Thoroughly clean the bores of steel balls.

4. Place the steel ball (3) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 15 00
5. Place the steel ball (1) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 1500
6. Warm up the engine and check the oil for leaks.

Installation of Screw Plug
Notice
If steel ball leaks again, install the screw plug.
1. Remove the steel ball.
2. Tap thread into the bores of the oil gallery.
Notice
Front bore : M18 ´ 1.5, depth 10mm
Rear bore : M16 ´ 1.5, depth 14mm
3. Thoroughly clean the oil gallery.
4. Tighten the front plug (5) with seal (4).
5. Apply Loctite 241 and then tighten the rear plug (2).
CYLINDER BORE MEASUREMENT
a Longitudinal Direction
b Transverse Direction
c, d, e. Measuring Point
1 Crankcase Contacting Surface

2 TDC of 1st Piston Ring
4 BDC of Ring
Service Data
Standard size Code letter ‘A’ 89.000 - 89.006mm
Code letter ‘X’ 89.006 - 89.012mm
Code letter ‘B’ 89.012 - 89.018mm
Wear limit in direction of travel and in transverse direction Max. 0.20mm
When new 0.01mm
Permissible deviation of cylinder shape Wear limit 0.05mm
Honing angle 50° ± 10°

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SECTION INDEX

MUSSO GENERAL INFORMATION 0B

FOREWORD DRIVE LINE/AXLE 3

This manual includes procedure for mainte-

All information, illustrations and specifications

The right is reserved to make changes at any STEERING 6

BODY AND ACCESSORIES 9

Daewoo Motor Company, Limited

Daewoo Motor Company, Limited

Section 2 Suspension Section 9 Body and Accessories

391-9 CHONG CHON-2DONG, PU PYUNG-GU,

SECTION 1A1 M162 GENERAL ENGINE INFORMATION

SECTION 2A SUSPENSION DIAGNOSIS

SECTION 3A FRONT DRIVE AXLE

SECTION 4A HYDRAULIC BRAKES

SECTION 5A AUTOMATIC TRANSMISSION

SECTION 6A POWER STEERING SYSTEM

SECTION 7B/C MANUAL CONTROL/SEMIAUTO

SECTION 8A SEAT BELTS

SECTION 9A BODY WIRING SYSTEM

Performance-Autumatic Transaxle (MB)

Performance-Autumatic Transaxle (BTRA)

Clutch - Manual Type

Auto Transmission (BTRA)

Tire and Wheel

VEHICLE DIMENSIONS AND WEIGHTS

STANDARD BOLTS SPECIFICATIONS

*Diameter ´ pitch in millimeters

MAINTENANCE AND REPAIR

MAINTENANCE SERVICES Spark Plug Wire Replacement

SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE)

SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE)

RECOMMENDED FLUIDS AND LUBRICANTS

VEHICLE IDENTIFICATION NUMBER SYSTEM

12~17.Production Serial Number

1.Type Approval No. 2.Vehicle Identification Number.

Manufacturer’s Plate Location

Diesel Engine Gasoline Engine

162 990 1 0 012345 662 920 1 0 012345

Serial Number Serial Number

0 : Manual T/M 0 : Manual T/M

0 : MUSSO 910 : Non-Intercooler Engine

Engine Number Location

Diesel Engine IL6 3200

VEHICLE LIFTING PROCEDURES

Vehicle Lifting Points

GENERAL ENGINE INFORMATION

ENGINE SPECIFICATIONS (Cont'd)

1 HFM Sensor 12 Intake Manifold

23 Camshaft Adjuster 27 Oil Pump Drive Chain

000 589 10 99 01 001 589 65 09 00

001 589 76 21 00 119 589 01 09 00

ENGINE CRANKING AT THE FRONT OF CRANKSHAFT

1 Vibration Damper Assembly 3 Bolt ................................................. 8.6 ± 0.9 Nm

COMPRESSION PRESSURE TEST

1 Compression Pressure Tester 3 Adaptor

Standard Service Data

CYLINDER PRESSURE LEAKAGE TEST

3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with

Permissible Pressure Leakage