Disassembly - Assembly
Disassembling and assembling engine
Disassembling and assembling engine, list
The topic "Disassembling and assembling engine" includes the items listed below, which are covered in their respective procedure articles.
Item 1 Disassembling and assembling intake distributor
Item 2 Removing and installing drive belt
Item 3 Removing and installing deflection rollers and tensioning roller for drive belt
Item 4 Removing and installing oil pump with coolant guide housing
Item 5 Removing and installing air/oil separator
Item 6 Removing and installing camshafts
Item 7 Disassembling and assembling cylinder head
Item 8 Disassembling and assembling crankcase halves
Item 9 Removing and installing pistons
Item 10 Disassembling and assembling intermediate shaft on bearing housing
Item 11 Disassembling and assembling bearing housing with crankshaft
Disassembling and assembling engine, items list and views
Items 1 - 3
Items 4 and 5
Items 6 - 8
Items 9 - 11
Disassembling and assembling engine
Disassembly
Note: Before the engine is fastened to the engine holder or assembly stand, detach and remove the thrust plate and flywheel.
1. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.
2. Detach thrust plate.
Note: In order to avoid deformation of the thrust plate housing, always loosen screws in several stages and in diametrically opposite sequence.
3. Remove thrust plate and drive plate.
4. Detach flywheel (Torx T55).
5. Fasten engine holder, special tool 9589, to the crankcase half of cylinder bank 1 - 3.
6. Undo the oil drain plug on the oil pan and drain off the engine oil. Use a hexagon socket wrench insert for 8 mm hexagon socket head bolts.
7. Remove engine carrier.
8. Remove drive belt. Mark the running direction with a colored pen. Relieve the belt tension. To do this, turn the tensioning roller (wrench size 24 mm) clockwise and simultaneously remove the belt from the drive pulleys.
9. Remove generator from bracket. To do this, undo upper right-hand fastening screw on generator (1) by approximately 3 turns. A gentle tap on the fastening screw loosens the front fastening bushing in the generator arm. Unscrew fastening screw (1) and fastening screw (2).
9.1 Turn generator clockwise and remove from bracket.
9.2 Disconnect electrical plug connection.
10. Remove supply tank of the power steering system. To do this, remove the fluid in the upper supply tank until below the joint.
Bayonet lock open
11. Turn bayonet lock in the direction indicated by the arrow and pull off the supply tank.
12. Remove fluid in lower supply tank.
13. Undo oil separator on the crankshaft.
14. Undo the intake distributor on the intake pipe supports and remove the complete intake system with oil separator. Remove engine wiring harness with oil vent line.
15. Pull out oil dipstick and undo guide for dipstick.
16. Undo two hexagon-head bolts (a/f 10 mm) on the oil filler neck. Pull oil filler neck out of the crankcase.
17. Undo intake pipe supports from the cylinder heads and remove completely with the fuel ring pipe.
18. Remove starter (width across flats 16 mm).
19. Loosen belt pulley on the hydraulic pump.
20. Detaching steering return line. In order to detach the line from the supply tank, push the red unlocking ring forward (arrows) and simultaneously pull out the line. Use two plastic spatulas to press the unlocking ring.
21. Detaching steering return line from the supply tank with tool. The line can also be detached using a commercially available tool. The removal tool from Messrs. Snap-On, for example, is recommendable. Insert tool between line and the red unlocking ring and unlock. Pull line to the rear and simultaneously press the tool against the red ring. Carefully protect the line against dirt and scratches with a cap.
22. Detach hydraulic pump and steering supply line.
Undo steering supply line (wrench size 17); simultaneously counter at the body (wrench size 27).
Undo three hexagon-head bolts (M8 x 12) and remove hydraulic pump to the rear.
23. Remove oil-water heat exchanger. Remove vent line. Undo four hexagon socket head bolts (a/f 5 mm).
24. Remove vacuum tank.
25. Remove knock sensors.
26. Remove holders for rear muffler.
27. Remove shields from cylinder heads.
28. Remove ignition coils.
29. Remove exhaust manifold.
30. Turn crankshaft clockwise until the bore 1 OT (top dead center) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595/1.
31. Check basic camshaft position of cylinder bank 1 - 3. Remove closure cap. The closure cap of cylinder bank 1 - 3 is located on the flywheel side. Ensure that the groove in the camshaft faces outward toward the cylinder head cover. View from the Wheel side
32. If the position of the camshafts is incorrect, remove fixing pin at the pulley and rotate the crankshaft 360° clockwise.
33. Relieve camshaft drive chains. Unscrew chain tensioner of cylinder bank 1 - 3. ("2 rings" identification on hexagon of chain tensioner and on cylinder head, a/f 32 mm).
34. Pull off camshaft closure caps at pulley side of cylinder head 1 - 3.
35. Prepare special tool, holding-down device 9643, for installation: Unscrew hexagon socket head bolts and replace with M8 x 25 hexagon-head bolts. Adjust insertion depth. Insertion depth for inlet camshaft 15 mm, insertion depth for outlet camshaft 17 mm.
36. Fit special tool, holding-down device 9643, on the cylinder head and fasten with a hexagon-head bolt M8 x 30.
Note: In order to prevent damage, it is essential to fit the holding-down device before detaching the cylinder head cover.
37. Detach and remove oil extraction pump at cylinder head 1 - 3 - on the flywheel side.
38. Unscrew hexagon-head bolts M6 x 20 (2 ea.). Remove closure cap from tensioning element (VarioCam).
39. Remove cylinder head cover. Loosen hexagon-head bolts from the outside to the inside. Detach the cylinder head cover by knocking it gently with a plastic hammer, and press off carefully.
40. Fasten special tool 9611, holding-down device for camshafts, with auxiliary screws M6 x 45.
41. Relieve camshaft tensioning element with special tool, tensioning screw 9632.
Note: Screw in tensioning screw only so far as to slightly relieve the chain.
42. Unscrew three fastening screws (M6 x 95) on tensioning element.
43. Undo four hexagon-head bolts (M6 x 15) on the chain sprocket.
44. Remove drive plate and sprocket wheel.
45. Detach two bearing saddles. Lever bearing saddles out of the guide sleeves.
46. Remove holding-down device (special tools 9611 and 9643).
47. Carefully lift the complete unit, camshafts with chain and tensioning element out of the cylinder head. The chain must not jump over. Perform reallocation during refitting if necessary.
48. Remove valve tappets.
49. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside, and remove the guide for the valve tappets.
50. Undo oil baffle (hexagon-head bolt M6 x 16).
Note: The oil baffle is fitted only on cylinder head 1 - 3.
51. Unscrew four pan-head screws M6 x 35 (with captive washers) in the area of the chain box.
52. Undo the upper fastening screw for guide rails. Use a 6 mm Allen key.
53. Loosen cylinder head screws from outside to inside and remove the cylinder head. Remove and dispose of cylinder head gasket.
54. Remove cylinder head from cylinder bank 4 - 6. Advance crankshaft 360° clockwise until the bore 1 OT (top dead center) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
55. Check camshaft adjustment at cylinder bank 4 - 6: The groove in the camshaft must face inward toward the crankcase.
View from the belt pulley side
56. Unscrew chain tensioner of cylinder bank 4 - 6. Identification "One" (without)
57. Carry out further disassembly steps on cylinder head 4 -6, as described for cylinder head 1 -3.
58. Loosen belt pulley. Undo hexagon-head bolt W16 x 1.5 x 60) with special tool 9594 (socket wrench insert), and hold with special tool 9593 (retaining device) at the same time.
59. Turn primary chain tensioner out of the crankcase (cylinder bank 4 - 6). "1 Ring" identification
60. Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the lock nut with the special tool 9110 (socket wrench insert) and hold with a screwdriver 7.0 x 1.1 at the slotted threaded pin at the same time.
61. Remove coolant guide housing with oil pump. Pull hexagon oil pump driver out of intermediates haft flange.
62. Detach guide rail and tensioning rail of cylinder bank 1 - 3 (flywheel side).
View from the belt pulley side
View from the flywheel side
63. Detach slide rails and tensioning rails of cylinder bank 4 - 6 (flywheel side).
View from the belt pulley side
View from the belt pulley side
64. Turn crankcase by 180°. Undo oil pan fastening screws (M6 x 16, 13 ea.). Detach oil pan by tapping it at the sides with a plastic hammer and lever the oil pan off at the leverage bar using a plastic-coated mounting lever.
65. Remove air/oil separator and oil suction pipe.
66. Turn crankcase by 180°. Undo fastening screws between crankcase half of cylinder bank 1 - 3 and bearing housing.
67. Undo fastening screw between crankcase half of cylinder bank 4 - 6 and bearing housing.
68. Turn crankcase 90° further. Crankcase half of cylinder bank 4 - 6 faces upward. Undo hexagon-head bolts (M6 x 35, 24 ea.) joining the crankcase halves.
Warning: Danger of damage to pistons if crankcase half is tilted!
^ Do not tilt crankshaft half
^ Lift the crankcase half up and off
^ Two people required to remove crankcase half
69. For the disassembly procedure, the crankcase half and bearing housing unit must be held by at least two screwed connections for safety reasons. For this purpose, fasten two original cylinder head screws and plastic spacer sleeves, special tool 9613. Tightening torque approximately 20 Nm (15 ft. lbs.). Use Torx screwdriver insert T50 or T55.
70. Identify pistons of cylinder 4 - 6. Lever off front piston pin circlip. Push out piston pin. Allocate the same corresponding pistons to the piston pins again after disassembly.
71. Remove pistons with connecting rods on cylinder bank 1 - 3. Mark pistons. Unscrew connecting-rod bolts. Remove twelve-edged socket wrench insert a/f 14 mm and connecting-rod bearing cap.
72. Push connecting rod with piston downwards out of the cylinder using a shop-made plastic mandrel.
Note: Join connecting rod and connecting-rod bearing cap again immediately after removal. The connecting-rod bearing caps must always remain allocated to the respective connecting rods and must never be interchanged.
73. Fasten assembly fixture (special tool 9607) on the bearing housing with two M10 x 25 hexagon-head bolts.
74. Remove plastic spacer sleeves, special tool 9613 again.
75. Fasten suspension eye, attach spring hook, and lift bearing housing out of the crankcase half using a workshop crane or engine lifter. Do not damage sealing surfaces when lifting out.
Note: The bearing housing and assembly fixture, special tool 9607, remain screwed together when disassembling the bearing housing and intermediate shaft.
76. Disassemble bearing housing on intermediate shaft.
77. Remove crankcase half cylinder bank 1 - 3 from the engine holder.