Section 126 (Engine - Overhaul Instructions)
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- Crank Mechanism (B5234T3; 2001-2004)
- Crank mechanism, assembling
- Notes
- Tightening torque
- Cleaning
- Installing the piston cooling valve and nozzles
- Classification of main bearings
- Selecting bearings
- The intermediate section
- Tightening the intermediate section
- Marking the connecting rod (where applicable)
- Installing piston rings
- Assembling pistons and connecting rods
- Installing the pistons in the cylinder bores
- Tightening the connecting rod cover
- Installing the oil pump suction pipe
- Installing the oil pan
- Installing the oil cooler
- Installing the rear crankshaft seal
- Disassembling the crankshaft assembly
- Notes
- Preparation
- Removing the oil filter and oil pan
- Removing the suction pipe from the oil pump
- Checking markings
- Marking the connecting rod (where applicable)
- New connecting rod
- Removing the pistons from the cylinder block
- Removing the screwed joint from the intermediate section
- Separating the intermediate section from the cylinder block
- Removing the piston cooling valve and nozzles
- Cleaning
- Measuring the crankshaft assembly
- Notes
- Measuring the crankshaft
- Check the out-of-true of the crankshaft
- Removing the piston rings
- Checking piston ring axial clearance
- Checking the piston diameter
- Calculating the running clearance of the piston
- Disassembling connecting rods and pistons
- Checking the alignment of the piston pins in the pistons
- Checking the alignment of the piston pins in the connecting rods
- New connecting rod
- Checking the bearing recess in the connecting rod big end
- Checking the connecting rod in a connecting rod aligner
- Crank mechanism, assembling
- Crank Mechanism (B5244S; 2001-2007)
- Crank mechanism, assembling
- Notes
- Tightening torque
- Cleaning
- Installing the piston cooling valve and nozzles
- Classification of main bearings
- Selecting bearings
- Intermediate part
- Tightening the intermediate section
- Marking the connecting rod (where applicable)
- Installing piston rings
- Assembling pistons and connecting rods
- Installing the pistons in the cylinder bores
- Tightening the connecting rod cover
- Installing the oil pump suction pipe
- Installing the oil pan
- Installing the oil cooler and oil filter
- Installing the rear crankshaft seal
- Disassembling the crankshaft assembly
- Notes
- Preparation
- Removing the oil filter and oil pan
- Removing the suction pipe from the oil pump
- Checking markings
- New connecting rod
- Removing the pistons from the cylinder block
- Removing the screwed joint from the intermediate section
- Separating the intermediate section from the cylinder block
- Removing the piston cooling valve and nozzles
- Cleaning
- Measuring the crankshaft assembly
- Notes
- Measuring the crankshaft
- Check the out-of-true of the crankshaft
- Removing the piston rings
- Checking the axial clearance of the piston rings
- Checking the piston diameter
- Calculating the running clearance of the piston
- Disassembling connecting rods and pistons
- Checking the alignment of the piston pins in the pistons
- Checking the alignment of the piston pins in the connecting rods
- New connecting rod
- Checking the bearing recess in the connecting rod big end
- Checking the connecting rod in a connecting rod aligner
- Crank mechanism, assembling
- Crank Mechanism (B5244S6; 2003-2006)
- Crank Mechanism (B5244T3; 2001-2003)
- Crank Mechanism (B5244T5; B5254T2; 2005-2007)
- Crank mechanism, assembling
- Notes
- Cleaning
- Installing the piston cooling valve and nozzles
- Classification of main bearings
- Selecting bearings
- Applying liquid gasket
- Tightening the intermediate section
- Marking the connecting rod (where applicable)
- Selecting piston
- Installing piston rings
- Assembling pistons and connecting rods
- Installing the main bearing shells
- Installing the pistons in the cylinder bores
- Tightening the connecting rod cover
- Installing the oil pump suction pipe
- Installing the sump
- Installing the oil cooler
- Installing the rear crankshaft seal
- Crankshaft assembly, disassembling
- Notes
- Preparation
- Removing the oil filter and oil pan
- Removing the suction pipe from the oil pump
- Checking markings
- New connecting rod
- Removing the pistons from the cylinder block
- Check
- Removing the screwed joint from the intermediate section
- Separating the intermediate section from the cylinder block
- Removing the piston cooling valve and nozzles
- Cleaning
- Crank mechanism, assembling
- Crank Mechanism (B5254T2; 2003-2004)
- Crank Mechanism (B5254T4; 2004-2007)
- Crank Mechanism (B5254T4, TF-80SC AWD; 2006-2007)
- Cylinder Block (B5234T3; 2001-2004)
- Cylinder Block (B5244S; 2001-2007)
- Cylinder Block (B5244S6; 2003-2006)
- Cylinder Block (B5244T3; 2001-2003)
- Cylinder Block (B5254T2; 2003-2004)
- Cylinder Head (B5234T3; 2001-2004)
- Cylinder Head (B5244S; 2001-2007)
- Cylinder Head (B5244S6; 2003-2006)
- Cylinder Head (B5244T3; 2001-2003)
- Cylinder Head (B5244T5; B5254T2; 2005-2007)
- Cylinder Head (B5254T2; 2003-2004)
- Cylinder Head (B5254T4; 2004-2007)
- Cylinder Head (B5254T4, TF-80SC AWD; 2006-2007)
- Timing Belt Assembly (B5254T4; 2004-2007)
- Timing Belt Drive, assembly
- Notes
- Tightening torque
- Installing the water pump
- Installing the oil pump
- Installing front crankshaft seal
- Installing the crankshaft timing gear pulley
- Installing the idler pulley and belt tensioner
- Installing the timing gear pulley for the camshafts
- Installing the variable valve timing (VVT) unit on the intake camshaft
- Finishing
- Installing the timing belt
- Adjusting the timing belt
- Checking the markings and belt tension
- Installing the vibration damper
- Timing Belt drive, dismantling
- Notes
- Aligning the engine according to the marking
- Removing the vibration damper
- Removing the timing belt
- Removing the crankshaft pulley
- Removing the belt tensioner and idler pulley
- Removing the oil pump
- Checking the oil pump
- Assembling the oil pump
- Removing the coolant pump/timing belt cover
- Removing the thermostat and thermostat housing
- Checking the opening function of the thermostat
- Timing Belt Drive, assembly
- Timing Belt Assembly (B5254T4, TF-80SC AWD; 2006-2007)
- Timing Belt Assembly (B5244S; 2001-2007)
- Timing Belt drive, assembly
- Dismantling the timing belt transmission
- Notes
- Aligning the engine according to the marking
- Removing the vibration damper
- Removing the timing belt
- Removing the crankshaft pulley
- Removing the belt tensioner and idler pulley
- Removing oil pump
- Checking the oil pump
- Removing the coolant pump / timing belt cover
- Removing the thermostat / thermostat housing
- Checking the opening function of the thermostat
- Timing Belt Assembly (B5244S6; 2003-2006)
- Engine Block Assembly (B5234T3; 2001-2004)
- Engine Block Assembly (B5244S; 2001-2007)
- Engine Block Assembly (B5244S6; 2003-2006)
- Engine Block Assembly (B5244T3; 2001-2003)
- Engine Block Assembly (B5254T2; 2003-2007)
- Engine Block Assembly (B5254T4; 2004-2007)
- Engine Block Assembly (B5254T4, TF-80SC AWD; 2006-2007)
- Timing Gear (B5244T5; B5254T2; 2005-2007)
- Belt drive, assembly
- Notes
- Tightening torque
- Installing the water pump
- Installing the oil pump
- Installing front crankshaft seal
- Installing the crankshaft timing gear pulley
- Installing the idler pulley and belt tensioner
- Installing the timing gear pulley for the camshafts
- Installing the variable valve timing (VVT) unit on the intake camshaft
- Finishing
- Installing the timing belt
- Adjusting the timing belt
- Checking the markings and belt tension
- Installing the vibration damper
- Belt drive, dismantling
- Belt drive, assembly
- Timing Belt Transmission Assembly (B5234T3; 2001-2004)
- Timing Belt transmission, assembly
- Notes
- Tightening torque
- Installing the water pump
- Installing the oil pump
- Installing the crankshaft timing gear pulley
- Installing the idler pulley and belt tensioner
- Installing the timing gear pulley for the camshafts
- Installing the timing belt
- Installing the vibration damper
- Checking the markings and belt tension
- Dismantling the timing belt transmission
- Notes
- Aligning the engine according to the marking
- Removing the vibration damper
- Removing the timing belt
- Removing the crankshaft pulley
- Removing the belt tensioner and idler pulley
- Removing oil pump
- Checking the oil pump
- Removing the coolant pump / timing belt cover
- Removing the thermostat and thermostat housing
- Checking the opening function of the thermostat
- Timing Belt transmission, assembly
- Timing Belt Transmission Assembly (B5244T3; 2001-2003)
- Timing Belt Transmission Assembly (B5254T2; 2003-2004)
- Caulking (B5234T3; 2001-2004)
- Caulking (B5244S; 2001-2007)
- Caulking (B5244S6; 2003-2006)
- Caulking (B5244T3; 2001-2003)
- Caulking (B5244T5; 2005-2007)
- Caulking (B5254T2; 2003-2007)
- Caulking (B5254T4; 2004-2007)