Part 1
WM 100137 Disassembling and assembling engine
Preliminary work for disassembling engine
Preliminary work for disassembling engine
1. Remove engine.
2. Remove transmission.
3. Remove exhaust manifold.
Tiptronic transmission:
4. Remove drive plate for converter.
Manual transmission:
5. Remove clutch.
6. Remove flywheel.
Component overview-engine
Component overview-engine
Information
The overview graphics are shown schematically and may be different to how the components actually look.
Intake system, belt drive
Overview of intake system, belt drive
^ 1 - Intake distributor
^ 2 - Belt drive
^ 3 - Belt guide and belt tensioner
Engine lubrication, engine cooling
Overview of cooling, lubrication
^ 4 - Oil pump, heat exchanger, water pump, coolant guide housing
^ 5 - Oil pan, oil separator
Cylinder head, crankcase
Overview of cylinder head, crankcase
^ 6 - Cylinder-head cover, camshafts, flat-base tappet housing, cylinder head
^ 7 - Cylinder head, flat-base tappets
^ 8 - Crankcase halves
Crank drive, pistons
Overview of crank drive, pistons
^ 9 - Pistons, connecting rods
^ 10 - Bearing housing with intermediate shaft
^ 11 - Bearing housing halves with crankshaft
Disassembling engine down to crankcase
Disassembling engine down to crankcase
Caution
Risk of damage due to particles of dirt.
^ Danger of material damage due to blocked oil bores/oil ducts.
-> Absolute cleanliness is essential when working on the engine.
-> Lay removed engine parts on a clean base and make sure to cover them.
-> Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Warning
Coolant is corrosive and hazardous to health.
^ Risk of skin and eye irritation.
-> Wear protective gloves and goggles.
-> If you come into contact with coolant, wash off immediately with plenty of warm water.
Warning
Pentosin is hazardous to health
Danger of material damage and injury
-> Wear protective gloves and goggles.
-> If the eyes or skin come into contact with the fluid, wash immediately with water.
-> Collect emerging Pentosin. Clean hoses which come into contact with Pentosin thoroughly.
-> Use caps to protect the wiring against soiling and damage.
Warning
Danger due to oil draining out and spraying when the engine is hot.
^ Danger of scalding and injury
-> Allow engine to cool down.
-> Wear specified protective gear.
Information
^ The central screws of the camshaft adjustment elements must be undone before removing the cylinder head cover.
Information
^ The bearing housing remains screwed to the retaining device when the bearing housing and intermediate shaft are disassembled.
1. Engine support 9589 must be secured to the crankcase using special tool mounting elements 9590. Refit engine with support on the engine assembly support.
Engine support
2. Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8).
Oil drain plug
3. Remove pulley -2- of power-steering pump; to do this, counter the pulley -2- as shown using a screwdriver, then remove three Torx screws (M8 x 12) -1-.
Pulley on power-steering pump
4. Disconnect cable plug -2- of solenoid valves -3-.
5. Disconnect cable plug -4- of engine-temperature sensor -5-.
6. Disconnect cable plug -1- of all fuel injector valves.
Engine compartment temperature sensor
7. Disconnect cable plug-Arrow- for carbon canister solenoid valve.
Carbon canister valve
8. Loosen support for servo lines -2- by unclipping the oxygen sensor line from the support -3- and unscrewing two Torx screws (M6 x 12) -1-.
Servo line supports
9. Unscrew six fastening screws (M6 x 35) for each intake-air distributor.
10. Completely remove the intake bridge. Replace gaskets during installation.
11. Remove drive belt cover by unscrewing three Torx screws (M6 x 12) -Arrows-.
Cover for pulley
12. Disconnect cable plug -1- on generator.
13. Unscrew collar nut (M8) -2- and remove ground B+ line -3-.
Generator connections
14. Remove generator -3- by unscrewing the Torx screws (M10 x 35) -1- and (M10 x 145) -2-. The deflection roller is removed together with the generator (-3-).
Generator
15. Remove oil filler neck -2- by unscrewing two Torx screws (M6 x 11) -1-. Replace O-ring and screws during installation.
Oil filler neck
16. Unscrew union nut of servo pressure line (a/f 16) -1-.
17. Remove power-steering pump with the lines by unscrewing three Torx screws (M8 x 30) -3- and the Torx screw (M8 x 12) -2-.
Fastening screws for power-steering pump
18. Remove power-steering pump support -2- by unscrewing four Torx screws (M8 x 35) -1-. The power-steering pump support -2- is also fixed with roll pins; if necessary use a rubber hammer for the removal.
Power-steering pump support
19. Remove the positive crankcase ventilation line -1- by releasing and disconnecting the rapid-action couplings -Arrows-. Replace O-rings during installation.
Positive crankcase ventilation line
20. Unscrew collar nut (M8) -1- and remove terminal 30 line -2-.
21. Unscrew collar nut (M6) -3- and remove terminal 50 line -4-.
Electric leads on starter
22. Remove engine wire harness; to do this, remove all remaining cable plugs, unscrew Torx screws (M6 x12) -1- of the ground straps -2- and unscrew two Torx screws (M6 x 12) and (M8 x 20) for each of the plastic cable wire harness guides.
Ground lead
Support
23. Remove oil-water heat exchanger -1- by unscrewing four Torx screws (M6 x 16) -2-. Replace all O-rings during installation.
Heat exchanger
24. Remove oil mist separator -3- by unscrewing two Torx screws (M6 x 20) -1- and loosening the spring band clamp -2-. Pull oil mist separator -3- from the cylinder head and pull off the hose. Replace O-ring during installation.
Oil mist separator
25. Unscrew three Torx screws (M6 x 20) -1- on the bracket for the secondary air pump.
Secondary air pump with bracket
26. Unscrew two Torx screws (M6 x 20) -1- on the flange of the secondary air pump -2-. Remove secondary air pump. Replace both metal seals during installation.
Secondary air line
27. Remove starter -2- by unscrewing two Torx screws (M10 x 35) -1-.
Starter
28. Remove knock sensors -2- by unscrewing one Torx screw (M8 x 35) on each -1-. Mark the position of the electric connection for re-installation.
29. Unscrew oil level sensor with a ring wrench (a/f 19) -3-. Replace copper sealing ring during installation.
30. Remove spacer sleeve -4-.
View of knock sensors
31. Unscrew oil pressure sender with a ring wrench (a/f 24) -1-. Replace aluminum sealing ring during installation.
Oil pressure sender
32. Remove connection piece for positive crankcase ventilation -2- by unscrewing two Torx screws (M6 x 11) -1-. Replace O-ring during installation.
Connection piece for positive crankcase ventilation
33. Remove both hall senders -2- by unscrewing one Torx screw (M6 x 11) on each -1-. Replace O-rings during installation.
Hall sender
34. Remove deflection roller by unscrewing the Torx screw (M8 x 60). Check deflection roller for damage, wear and smooth operation.
35. Remove engine ground strap on cylinder 1-3 by unscrewing the Torx screw (M8 x 30).
36. Remove crankshaft belt pulley by countering the belt pulley with special tool retaining device 9593 and screwing out central screw (M16 x 60).
Screw on pulley
37. Remove engine mounting by unscrewing the three hexagon-head bolts (M10 x 120) and the hexagon-head bolt (M10 x 80). Only loosen the left upper hexagon-head bolt (M10 x 120); the hexagon-head bolt can be unscrewed after the engine mounting has been removed.
38. Tiptronic only: Remove clip for belt routing by unscrewing two Torx screws (M6 x 12).
39. Remove coolant guide housing by unscrewing five external Torx screws (M6 x 35) and three internal Torx screws (M6 x 20). Replace O-rings during installation.
40. Remove ignition coils -1- by unscrewing two Torx screws (M6 x 25) -2-.
Ignition coil
41. Remove crankshaft pulse sender -1- by unscrewing the Torx screw (M6 x 15) -2-.
Crankshaft pulse sender
42. Remove coolant lines -1- and -2- by unscrewing two Torx screws (M6 x 16) -3-.
Coolant lines
43. Remove coolant pump by unscrewing six hexagon-head bolts (M6 x 25, M6 x 30) -Arrows-. Replace metal seal during installation.
Coolant pump
44. Remove thermostat housing. Unscrew four Torx screws (M6 x 20) and remove housing complete with thermostat. Replace seal during installation.
45. Remove tandem pump by unscrewing four Torx screws (micro-self-locking, M6 x 30) -Arrows-. During installation, note the position of the pump drive with respect to the groove on the camshaft sprocket. Both parts must be in line in installation position. Otherwise the pump drive must be rotated. Replace O-ring and screws during installation.
Tandem pump
Pump drive
46. Remove solenoid hydraulic valve for camshaft adjustment.
47. Remove coolant adapter by unscrewing six Torx screws (M6 x 20) -Arrows-. Replace metal seal during installation.
Coolant adapter
48. Remove brackets for oxygen sensor cables by unscrewing five Torx screws (M6 x 12) -Arrows-.
Brackets for oxygen sensors 1 - 3
Brackets for oxygen sensors 4 - 6
49. Remove all remaining plastic accessories (clips, supports etc.).
50. Remove transport eyebolt -1- by unscrewing two Torx screws (M6 x 16) -2-.
51. Remove supports -3- by unscrewing one Torx screw (M6 x 12) -4-.
Assembly eye