vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Diesel Engine|Description and Operation > < Recommended Torque Values

Astra G

Repair an engine using a part-engine

  Remove

1.   Remove engine
•   For X 20 DTL, Y 20 DTL and Y 20 DTH up to MY 2003 LUREF_1.gif
•   For Y 20 DTH as of MY 2003 and Y 22 DTR LUREF_1.gif
2.   Mount engine on engine assembly stands KM-412-A
3.   Drain engine oil
•   Place collecting basin underneath
•   Remove oil drain bolt
4.   Remove charge air pipe
•   2 fastening bolts (2)
•   1 clamp (1)
Object Number: 2404461 Size: DEFAULT


5.   Unclip coolant hose (2)
•   Remove engine wiring harness bracket
6.   Detach wiring trough (1)
•   Remove 2 bolts
Object Number: 2404492 Size: DEFAULT


7.   Remove engine wiring harness bracket
•   Remove 2 bolts (arrows)
Object Number: 2404493 Size: DEFAULT


8.   Remove engine wiring harness
•   from alternator
– 2 nuts
•   from starter
– 2 nuts
•   Remove 2 turbocharge control vacuum hoses
– from vacuum reservoir, solenoid valve
•   Detach wiring harness plug for glow plugs (2)
– Use KM-717 (1)
Important:   Close 2 engine control unit connectors. Use KM-6154
•   Disconnect wiring harness plug
– Oil pressure switch, intake pipe pressure sensor, crankshaft pulse pickup, EGR valve, 2x engine control unit, coolant temperature sensor, dynamic oil level control sensor, oil temperature sensor, compressor
Object Number: 2404497 Size: DEFAULT


9.   Detach ribbed V-belt
Note:   Mark direction of rotation
•   Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow)
•   Remove ribbed V-belt
Object Number: 2394948 Size: DEFAULT


10.   Remove ribbed V-belt tensioner
Important:   Damper (3) may only be stored in upright position. Incorrectly stored dampers may be bled by repeated compression in installation position.
•   2 fastening bolts (1) and (2)
Object Number: 2395991 Size: DEFAULT


11.   Remove alternator
•   2 fastening bolts
•   1 fastening nut
•   Remove coolant hose bracket
12.   Remove compressor (1)
•   3 fastening bolts
13.   Remove compressor main bracket
•   Detach KM-6313-10 (2)
– 1 fastening bolt
•   2 fastening bolts
Object Number: 2405494 Size: DEFAULT


14.   Remove right engine bracket
•   3 fastening bolts
15.   Remove timing case cover (1)
Important:   Carefully separate timing case cover from timing case using wide spatula (2) Do not lever off timing case cover or use force to separate it from timing case, as permanent deformation results in leakage.
•   6 fastening bolts
Object Number: 2394942 Size: DEFAULT


16.   Remove turbocharger heat shield
•   3 fastening bolts (1)
17.   Remove 2 exhaust manifold heat shields
•   2 fastening bolts (2)
Note:   Carefully remove right heat shield upwards
Object Number: 2404499 Size: DEFAULT


18.   Detach turbocharger oil feed line (1)
•   Place collecting basin underneath
•   Remove union nut
Object Number: 2404495 Size: DEFAULT


19.   Remove exhaust manifold support
•   Release upper bolt
•   Remove lower bolt
20.   Detach turbocharger oil return line
•   From cylinder block connecting branch
– 1 union nut
21.   Remove starter
•   1 fastening bolt
22.   Detach upper bracket for alternator (coolant flange)
•   3 fastening bolts (1)
•   Remove gasket.
Object Number: 2405495 Size: DEFAULT


23.   Remove cylinder block coolant flange (2)
•   Release clamp
•   Detach coolant hose (1)
•   Remove 2 bolts
•   Remove gasket.
Object Number: 2399585 Size: DEFAULT


24.   Loosen ribbed V-belt pulley crankshaft (1)
Note:   Second installer required
•   Loosen bolt
– Up to MY 2003 and engine number 17K44148: Counterhold using KM-977-1 (2) together with KM-956-1
– From MY 2003 and engine number 17K44149: Counterhold using KM-6619 (2) together with KM-956-1
Object Number: 2405500 Size: DEFAULT


25.   Remove crankshaft ribbed V-belt pulley
•   Unscrew bolt
26.   Remove clutch
27.   Remove flywheel
•   Use KM-652 (1)
•   10 fastening bolts
Object Number: 2405496 Size: DEFAULT


28.   Remove throttle valve connecting piece
Note:   For engines with throttle valve vacuum unit (2): Detach vacuum hose
•   4 fastening bolts (1)
•   Remove bracket
•   Remove gasket.
Object Number: 2405497 Size: DEFAULT


29.   Remove injection line bracket
Note:   Mark position of the bracket
•   2 fastening bolts (arrows)
30.   Remove injection lines (1)
•   8 union nuts
•   Use KM-6098
Note:   Note installation position.
Object Number: 2405498 Size: DEFAULT


31.   Detach thermostat housing (1)
•   Detach coolant hose
– 1 clamp
•   4 fastening bolts
•   Remove gasket.
Object Number: 2405499 Size: DEFAULT


32.   Remove oil dipstick tube
•   1 fastening bolt
Important:   Collect escaping fuel
33.   Remove 2 fuel lines (1)
•   Disconnect leak oil hose (2)
•   2 banjo bolts (3)
Object Number: 2404491 Size: DEFAULT


34.   Detach vacuum line
•   From switchover valves vacuum unit
•   Unclip from brackets
35.   Remove vacuum pump (2)
•   4 fastening bolts (1)
•   Remove gasket (3)
Object Number: 2402003 Size: DEFAULT


36.   Disconnect cylinder head cover.
•   8 fastening bolts
•   Remove gasket.
37.   Tighten oil drain bolt
•   Replace seal ring
– Tightening torque 10 Nm / 7.5 lbf. ft.
38.   Remove crankshaft pulse pickup (1)
•   1 fastening bolt
•   Remove Seal ring
Object Number: 2404471 Size: DEFAULT


39.   Attach crankshaft ribbed V-belt pulley bolt
40.   Set engine to no.1 cylinder Ignition TDC
Note:   Turn crankshaft uniformly evenly in direction of engine rotation. Mark on torsional vibration damper (3) must be positioned just before lug (2) on timing case. Both cylinder 1 (1) cams must point upwards
Object Number: 2399960 Size: DEFAULT


41.   Use KM-929 (1)
Note:   Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).
Object Number: 2396165 Size: DEFAULT


42.   Use KM-927 (3)
Note:   Arrow (1) on Simplex injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.
Object Number: 2395988 Size: DEFAULT


43.   Use KM-932 (3)
Note:   Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).
Object Number: 2395989 Size: DEFAULT


44.   Remove Simplex chain tensioner (3)
Note:   Note installation position.
•   Remove bolt (1), seal ring (2), chain tensioner (3)
Object Number: 2404485 Size: DEFAULT


45.   Remove guide rail for Simplex chain tensioner (1)
Important:   Heat bolts intensively with hot air blower and remove. Use suitable heat shielding
•   2 fastening bolts (2)
•   Remove guide rail upwards
Note:   Note installation position.
Object Number: 2395997 Size: DEFAULT


46.   Remove KM-927 and KM-932
47.   Remove camshaft sprocket
•   Remove 1 bolt
Note:   Counterhold camshaft at hexagonal section. Attach Simplex timing chain at a suitable place.
Object Number: 2396000 Size: DEFAULT


48.   Loosen cylinder head
Important:   Loosen cylinder head bolts in illustrated sequence by first 1/4, then 1/2 turn
•   4 fastening bolts (M8) (arrows)
Note:   Observe different bolt lengths
•   10 fastening bolts (M12)
Object Number: 2394952 Size: DEFAULT


Important:   Place cylinder head on wooden blocks. Do not damage injectors, glow plugs or valves.
49.   Remove cylinder head.
Note:   2nd mechanic is required.
50.   Remove cylinder head gasket
51.   Remove Duplex chain tensioner (3)
Note:   Note installation position.
•   Remove bolt (1), seal ring (2), chain tensioner (3)
Object Number: 2404486 Size: DEFAULT


52.   Remove Simplex injection pump gear
•   4 fastening bolts (1)
•   Lower Simplex timing chain downwards
•   Remove Simplex injection pump gear at side
•   Remove Simplex timing chain upwards
Object Number: 2399580 Size: DEFAULT


53.   Release injection pump
•   Remove 4 fastening bolts (1)
•   Use MKM-604-30
54.   Remove engine block coolant drain connection
•   Place collecting basin underneath
55.   Remove injection pump
•   Remove cylinder block bolt
– From bracket (2)
Object Number: 2396070 Size: DEFAULT


56.   Remove coolant pump
•   Place collecting basin underneath
•   Ribbed V-belt pulley (1)
– 3 fastening bolts
•   Coolant pump (2)
– 3 fastening bolts
Object Number: 2396059 Size: DEFAULT


57.   Rotate engine 180°
58.   Remove oil pan
•   17 fastening bolts
•   Remove gasket.
59.   Detach balancer shaft unit cover (1)
•   4 fastening bolts
60.   Use KM-978 and KM-979
•   Set engine to no.1 cylinder Ignition TDC
•   Insert KM-979 (3)
Note:   At side in balancer shaft unit
•   Insert KM-978 (2)
Note:   Push back chain tensioner by hand. Insert KM-978 into bores
61.   Detach sprocket (4)
•   1 fastening bolt (5)
Object Number: 2399569 Size: DEFAULT


62.   Detach balancer shaft unit
Important:   Release bolts from outside inwards
•   7 fastening bolts (1), (2)
Note:   Guide rail (4) and chain tensioner (3) must be transferred when replacing the balancer shaft unit
Object Number: 2400027 Size: DEFAULT


63.   Rotate engine 90°
64.   Remove crankshaft ribbed V-belt pulley bolt
65.   Remove timing case
•   13 fastening bolts
Note:   Observe different bolt lengths
66.   Detach slide rail (5)
•   1 fastening bolt
67.   Detach guide rail for Duplex timing chain (3)
•   3 fastening bolts
68.   Remove Duplex chain drive
•   Timing chain (2), crankshaft pulley (4), injection pump gear (1)
69.   Remove timing case gasket (6)
Object Number: 2396037 Size: DEFAULT


Important:   Edge seal ring out of timing case with suitable tool – ensure that the sealing surfaces are not damaged
70.   Remove crankshaft front seal ring, timing case seal ring
71.   Remove cylinder block
•   Use KM-2358
•   Suspend engine on workshop crane.
•   Detach from KM-412-16 and KM-412-8-1
– 6 fastening bolts

  Install

72.   Attach cylinder block
•   Use KM-2358
•   Raise engine.
•   Attach KM-412-16 and KM-412-8-1 to engine
– 6 fastening bolts
– Detach KM-2358
73.   Clean sealing surfaces
•   Timing case, cylinder block, cylinder head, oil pan
74.   Inspect components
75.   Clean thread.
•   2x simplex chain adjuster safety rails
•   6x clutch pressure plates
Important:   A spacer washer (1) may be installed on the injection pump flange (2) to adjust the axial dimension. This spacer washer is allocated to the corresponding fuel injection pump and must always be left on the fuel injection pump flange. When installing a new fuel injection pump, this is supplied with the axial dimension adjusted, i.e. with or without spacer washer (1)
76.   Insert injection pump.
•   Replace seal ring
•   4 fastening bolts (3)
77.   Secure injection pump
•   4 fastening bolts (3)
– Use MKM-604-30
– Tightening torque 25 Nm / 18.5 lbf. ft.
•   Attach injection pump bracket
– Tightening torque 20 Nm / 15 lbf. ft.
Object Number: 2399947 Size: DEFAULT


78.   Attach engine block coolant drain connection
•   Replace seal ring
79.   Rotate engine 180°
80.   Use KM-929
•   Attach crankshaft ribbed V-belt pulley bolt
Important:   Pull balancer shaft unit chain upwards
•   Turn crankshaft to no.1 cylinder Ignition TDC
•   Remove crankshaft ribbed V-belt pulley bolt
81.   Rotate engine 90°
82.   Insert timing case gasket (1)
Important:   Note guide sleeves. Injection pump flange recess (2) must align with injection pump retaining bore (3)
•   Replace gasket
Object Number: 2396041 Size: DEFAULT


Important:   Ensure that recess is positioned in injection pump flange and that injection pump retaining bore (1) is centrally positioned in oblong hole (2) on duplex injection pump gear – tension side (I) must be taut.
83.   Insert Duplex chain drive
Note:   Check state of crankshaft pulley spring washer, replace if necessary. Place crankshaft pulley (6) with Duplex timing chain (5) and Duplex fuel injection pump gear (3) on crankshaft or fuel injection pump flange
84.   Attach guide rail for Duplex timing chain (4)
•   3 fastening bolts
– Tightening torque 8 Nm / 6 lbf. ft.
85.   Attach 2x tension rail (7)
•   1 fastening bolts
– Tightening torque 20 Nm / 15 lbf. ft.
Object Number: 2396042 Size: DEFAULT


86.   Attach timing case.
•   13 fastening bolts
Note:   Observe different bolt lengths. Tighten bolts uniformly
– Tightening torque 20 Nm / 15 lbf. ft.
87.   Install crankshaft front seal ring, timing case seal ring
•   Use KM-935-1 (1)
Note:   Position seal ring straight in timing case
•   Use KM-935-2 (2)
Note:   Press in seal ring until it lies flush in timing case. Use crankshaft ribbed V-belt pulley bolt
Object Number: 2396036 Size: DEFAULT


88.   Rotate engine 90°
89.   Attach balancer shaft unit
Note:   Guide rail (4) and chain tensioner (3) must be transferred when replacing the balancer shaft unit. Tighten bolts from inside outwards
•   7 new fastening bolts
•   2 fastening bolts (2)
– Tightening torque 20 Nm / 15 lbf. ft. + 60°
•   5 fastening bolts (1)
– Tightening torque 20 Nm / 15 lbf. ft. + 30°
Object Number: 2400027 Size: DEFAULT


90.   Attach sprocket
•   1 new fastening bolt
– Tightening torque 90 Nm / 66 lbf. ft. + 30°
91.   Remove KM-978 and KM-979
92.   Attach balancer shaft unit cover
•   4 fastening bolts
– Tightening torque 8 Nm / 6 lbf. ft.
93.   Apply adhesive sealant
Note:   Apply a bead of adhesive sealing compound to joints (arrows) of timing case and rear crankshaft bearing cap
Object Number: 2396051 Size: DEFAULT


94.   Install oil pan
Important:   Hand-tighten all bolts
•   Replace gasket
•   To cylinder block, timing case
– 17 fastening bolts
– Tightening torque 20 Nm / 15 lbf. ft.
95.   Rotate engine 90°
Important:   Clean thread in crankshaft before attaching flywheel
96.   Install flywheel
•   Use KM-652
•   10 new fastening bolts
– Tightening torque 45 Nm / 33 lbf. ft. + 30° + 15°
97.   Install clutch
98.   Rotate engine 180°
99.   Fasten crankshaft ribbed V-belt pulley
•   Screw in new bolts
100.   Fasten ribbed V-belt pulley crankshaft
Note:   2nd mechanic is required.
•   Tighten bolt 150 Nm + 45° + 15°
– Up to MY 2003 and engine number 17K44148: Counterhold using KM-977-1 together with KM-956-1
– From MY 2003 and engine number 17K44149: Counterhold using KM-6619 together with KM-956-1
101.   Install coolant pump
Note:   Replace gasket
•   Coolant pump
– 3 fastening bolts
– Tightening torque 20 Nm / 15 lbf. ft.
•   Ribbed V-belt pulley
– 3 fastening bolts
– Tightening torque 20 Nm / 15 lbf. ft.
Important:   Arrow (2) on simplex injection pump sprocket must align with recess in injection pump flange and lock bore (3) in injection pump.
102.   Install Simplex injection pump gear
Note:   Insert Simplex timing chain with Simplex fuel injection pump gear and hand-tighten Simplex fuel injection pump gear with fastening bolts (1). Ensure bolt strength 10.9 of the fastening bolts
•   Use KM-927 (4)
103.   Tighten Simplex injection pump gear
•   Remove KM-927
•   4 fastening bolts (1)
– Tightening torque 28 Nm / 20.6 lbf. ft.
Object Number: 2400015 Size: DEFAULT


104.   Install Duplex chain tensioner
Note:   Note installation position. Closed side of chain tensioner (3) must point to tension rail
•   Replace gasket (2)
•   1 bolt (1)
– Tightening torque 60 Nm / 44 lbf. ft.
Object Number: 2404486 Size: DEFAULT


105.   Check for plane surface
Note:   Check sealing surfaces in length and width for deformation and check for warping along the diagonals
•   Cylinder head
Important:   Resurfacing of the cylinder head is not permitted.
– With straightedge, feeler gauge
– Measure cylinder head height
– Sealing surface to sealing surface: Dimension (I) = 140 mm
Object Number: 2396044 Size: DEFAULT


106.   Measure piston projection
•   Insert MKM-571-B (1) into KM-301 (2)
– Note pretension
•   Set dial to zero
– Place probe on cylinder block
•   Measure piston projection at all four pistons
Note:   Measure the projection at two different points (3) and (4) or (5) and (6) for each piston. To do this, place measuring bridge with the dial gauge above the cleaned piston head on the cylinder block. Determine the highest point by turning the crankshaft.
Object Number: 2396362 Size: DEFAULT


Important:   The largest determined piston projection is used for the selection of the cylinder head gasket with corresponding identification. The identification (notch) is located in position (1). Do not insert cylinder head gasket with sealing compound.
107.   Replace cylinder head gasket
•   Piston projection 0.51 – 0.60 mm
– Gasket with 1 notch
– Thickness of gasket 1.3 mm
•   Piston projection 0.61 – 0.70 mm
– Gasket with 2 notches
– Thickness of gasket 1.4 mm
•   Attach cylinder head gasket
– Note guide bushings
Object Number: 2396363 Size: DEFAULT


108.   Use KM-932 (3)
Note:   Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).
Object Number: 2395989 Size: DEFAULT


Important:   Approx. 60° before no.1 cylinder Ignition TDC
109.   Turn crankshaft
110.   Position cylinder head
Note:   2nd mechanic is required. Note Simplex timing chain
111.   Attach cylinder head
Note:   Replace cylinder head bolts
•   10 new cylinder head bolts
– Tightening torque 25 Nm / 18.5 lbf. ft. + 65° + 65° + 65° + 65° + 15°
– Use KM-470-B
Note:   Note tightening sequence.
•   4 new fastening bolts (arrows)
– Tightening torque 20 Nm / 15 lbf. ft. + 30° + 5°
Object Number: 2395996 Size: DEFAULT


112.   Set engine to no.1 cylinder Ignition TDC
Note:   Turn crankshaft uniformly evenly in direction of engine rotation. Mark on torsional vibration damper (3) must be positioned just before lug (2) on timing case. Both cylinder 1 (1) cams must point upwards
Object Number: 2399960 Size: DEFAULT


113.   Use KM-929 (1)
Note:   Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).
Object Number: 2396165 Size: DEFAULT


114.   Use KM-927 (3)
Note:   Arrow (1) on Simplex injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.
Object Number: 2395988 Size: DEFAULT


115.   Insert camshaft sprocket
•   Position Simplex timing chain
Important:   Ensure that the camshaft sprocket is not askew on the camshaft – camshaft sprocket must lie plane on the camshaft.
•   1 new fastening bolt
116.   Install guide rail for Simplex timing chain (1)
Important:   Note installation position of guide rail
•   2 new fastening bolts (2)
– Tightening torque 8 Nm / 6 lbf. ft.
Object Number: 2395997 Size: DEFAULT


117.   Attach KM-933 (4)
•   Insert carrier (1)
Note:   Position upright in camshaft pulley
•   2 fastening bolts
Important:   It must be possible to remove and install KM-927 under suction. If this is not possible, the pressure on the adapter plate must be slightly reduced using the adjustment screw (3).
118.   Adjust KM-933 (4)
Note:   Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3).
Object Number: 2400016 Size: DEFAULT


119.   Secure camshaft sprocket
•   Tighten fastening bolt
– Tightening torque 90 Nm / 66 lbf. ft. + 60° + 30°
120.   Install Simplex chain tensioner (3)
Note:   Note installation position.
•   Replace gasket (2)
•   1 bolt (1)
– Tightening torque 60 Nm / 44 lbf. ft.
Object Number: 2404485 Size: DEFAULT


121.   Remove KM-927 , KM-932 , KM-933 and KM-929
•   Remove KM-933
– 2 fastening bolts
– Remove carrier
122.   Turn crankshaft
Note:   Turn crankshaft slowly and uniformly two turns (720°) in direction of engine rotation until just before no. 1 cylinder Ignition TDC. Mark on crankshaft ribbed V-belt pulley (3) must be positioned just before lug (2) on timing case. Both cylinder 1 (1) cams must point upwards
Object Number: 2399960 Size: DEFAULT


123.   Use KM-929 (1)
Note:   Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).
Object Number: 2396165 Size: DEFAULT


124.   Use KM-927 (3)
Note:   Arrow (1) on Simplex injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.
Object Number: 2395988 Size: DEFAULT


125.   Use KM-932 (3)
Note:   Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).
Object Number: 2395989 Size: DEFAULT


126.   Remove KM-932 , KM-927 and KM-929
127.   Install crankshaft pulse pick-up
•   Replace seal ring
•   1 fastening bolt
– Tightening torque 8 Nm / 6 lbf. ft.
128.   Attach cylinder head cover
•   Replace gasket
Note:   Gasket (2) must be inserted in gap (1) between cylinder head cover and sleeve. Apply sealing compound to sealing surfaces (arrows)
•   8 fastening bolts
– Tightening torque 8 Nm / 6 lbf. ft.
Object Number: 2404463 Size: DEFAULT


129.   Install vacuum pump
•   Replace gasket
•   4 fastening bolts
– Tightening torque 8 Nm / 6 lbf. ft.
130.   Attach vacuum line
•   To vacuum unit switchover valves
•   Clip on 2 brackets
131.   Install 2 fuel lines
•   Replace 4 gaskets
•   2 banjo bolts
– Tightening torque 25 Nm / 18.5 lbf. ft.
•   Connect leak oil hose
132.   Install oil dipstick guide tube
•   1 fastening bolt
– Tightening torque 8 Nm / 6 lbf. ft.
133.   Attach thermostat housing
•   Replace gasket
•   4 fastening bolts
– Tightening torque 8 Nm / 6 lbf. ft.
•   Attach coolant hose.
– Fasten clamp
134.   Install 4 injection lines
•   8 union nuts
Note:   Note installation position.
135.   Attach 2 injection line spacer washers
Note:   Note fitting positions
•   2 fastening bolts
136.   Tighten 4 injection lines
•   Use KM-6098
•   8 union nuts
– Tightening torque 30 Nm / 22 lbf. ft.
137.   Attach intake pipe
•   Replace gasket
•   Position upper engine cover bracket
•   4 fastening bolts
Note:   For engines with throttle valve vacuum unit: Connect vacuum hose
– Tightening torque 8 Nm / 6 lbf. ft.
138.   Attach cylinder block coolant flange
•   Replace seal ring
•   2 fastening bolts
– Tightening torque 20 Nm / 15 lbf. ft.
•   Fasten clamp
139.   Attach upper bracket for alternator (coolant flange)
•   Replace gasket
•   Tighten 3 bolts
– Tightening torque 20 Nm / 15 lbf. ft.
140.   Install starter
•   1 fastening bolt
– Tightening torque 45 Nm / 33 lbf. ft.
141.   Attach turbocharger oil return line
•   1 union nut
– Tightening torque 20 Nm / 15 lbf. ft.
142.   Attach exhaust manifold support
•   2 fastening bolts
– Tightening torque 25 Nm / 18.5 lbf. ft.
143.   Attach turbocharger oil feed line
•   Tighten union nut
– Tightening torque 20 Nm / 15 lbf. ft.
144.   Attach 2 exhaust manifold heat shields
•   2 fastening bolts
145.   Install turbocharger heat shield
•   3 fastening bolts
146.   Attach 3 heat shields
•   5 fastening bolts
– Tightening torque 8 Nm / 6 lbf. ft.
Important:   The application of silicone sealing compound, installation of timing case cover and tightening to torque must be performed within 10 minutes!
147.   Install timing case cover
Note:   Apply an approx. 2 mm (Dimension I) thick bead of silicone sealing compound to timing case cover
•   6 fastening bolts
– Tightening torque 6 Nm / 4.5 lbf. ft.
Object Number: 2396008 Size: DEFAULT


148.   Install right engine bracket
•   3 fastening bolts
– Tightening torque 55 Nm / 41 lbf. ft.
149.   Install compressor main bracket
•   2 fastening bolts
– Tightening torque 35 Nm / 26 lbf. ft.
•   Attach KM-6313-10
150.   Install compressor
•   3 fastening bolts
– Tightening torque 20 Nm / 15 lbf. ft.
151.   Install alternator
•   Position coolant hose bracket
•   2 fastening bolts and 2 fastening nuts
– Tightening torque 35 Nm / 26 lbf. ft.
152.   Install ribbed V-belt tensioner
•   2 fastening bolts
– Tightening torque (M8) 20 Nm / 15 lbf. ft.
– Tightening torque (M10) 42 Nm / 31 lbf. ft.
153.   Attach ribbed V-belt
Note:   Note running direction
•   Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow)
Object Number: 2404457 Size: DEFAULT


154.   Attach wiring harness bracket for engine management
•   2 fastening bolts
155.   Install wiring harness for engine management
•   Remove KM-6154
•   Connect wiring harness plug.
– Oil pressure switch, intake pipe pressure sensor, crankshaft pulse pickup, EGR valve, engine control unit, coolant temperature sensor, dynamic oil level control sensor, oil temperature sensor, compressor
•   Connect wiring harness plug for sheathed glow plugs
•   Attach 2 turbocharge control vacuum hoses
– Vacuum reservoir, solenoid valve
•   Starter
– 2 fastening nuts
•   Alternator
– 2 fastening nuts
156.   Attach wiring trough
•   2 fastening bolts
157.   Attach upper charge air pipe
•   1 clamp
– Tightening torque 3.5 Nm / 2.6 lbf ft
•   2 fastening bolts
– Tightening torque 3 Nm / 2 lbf. ft.
158.   Top up engine oil.
•   Observe specified engine oil quantity
Note:   After installing the engine, the engine oil level must be checked and corrected if necessary
159.   Remove engine from engine assembly stands KM-412-A
160.   Install engine
•   For X 20 DTL, Y 20 DTL and Y 20 DTH up to MY 2003 LUREF_1.gif
•   For Y 20 DTH as of MY 2003 and Y 22 DTR LUREF_1.gif
Related Literature Units
-
-

Diesel Engine|Description and Operation > < Recommended Torque Values