Disassembly
NOTE:
^ Step numbers below refer to numbers used in the illustrations.
^ Remove the engine and place on a suitable trolley.
1. Drain the oil and remove the starter motor.
2. Remove the belt tensioner, alternator and support bearing bracket complete with tube and inner drive-shaft joint.
3. Install holder tool No. 83 94 728, or equivalent, on the engine and lift the power train onto floor stand tool No. 78 74 878, or equivalent.
4. On models with automatic transmission, remove the protective plate and undo the torque converter retaining bolts.
- Rotate the flywheel by means of the crankshaft pulley to bring each bolt up to the opening where it can be removed.
5. Immobilize the torque converter by means of a 50-mm long fully-threaded M6 bolt.
6. On all models, remove the transmission
7. Disconnect the electric leads from the ignition discharge module, remove the oil filler pipe bracket and remove the preheating hoses from the throttle body.
8. Remove the bracket for the electric leads.
9. Undo the crankcase breather nipple and remove the intake manifold steady bar.
10. Remove the intake manifold retaining bolts and lift away the manifold.
11. Remove the bracket for the engine mounting.
12. Remove the filler pipe from the expansion tank.
13. Remove the heat exchanger pipe.
14. Remove the water pump complete with sleeve and O-rings.
15. Remove the crankcase breather pipe together with the inlet pipe (turbo).
16 Remove the turbo steady bar, disconnect the water and oil pipes (turbo) and remove the turbo unit.
17. Remove the power steering pump complete with bracket.
18. Remove the exhaust manifold.
- In regard to the two-piece exhaust manifold, first remove the inner section and then the outer section.
- Note that spacer sleeves are fitted on the outer studs only.
19. Remove the oil filter and adapter housing.
20. Remove the crankshaft sensor and unplug the oil level sensor connector.
21. Remove the thermostat housing cover.
22. Align the mark (0°) on the flywheel or driver disc with the mark on the end plate.
23. Install flywheel locking segment 83 94 868 and remove the crankshaft pulley.
24. Remove the flywheel locking segment and remove the flywheel or driver disc.
25. Remove the ignition discharge module or cover plate and disconnect the ignition cables (as equipped).
26. Remove the spark plugs and camshaft cover.
27. Remove the chain tensioner.
- First remove the plug and then use a suitable 27 mm socket.
28. Remove the camshaft sprockets and position the chain so that it will not obstruct removal of the cylinder head.
29. Remove the cylinder head.
- Start with the timing cover bolts and continue in reverse assembly order.
- Use protective collar tool No. 75 19 531, or equivalent, to collect the bolts.
30. Swivel the engine into a suitable position and remove the oil pan.
- Do not remove the guide sleeve from the cylinder block.
31. Remove the oil pump and the timing cover.
32. Remove the top chain guide and chain tensioner for the balance-shaft chain.
33. Remove the idler sprocket and balance-shaft chain.
34. Remove the oil pump driver and sprocket from the crankshaft.
35. Remove the chain guides for the balance-shaft and timing chains.
36. Remove the timing chain guard and remove the chain complete with sprocket.
NOTE: Rotate the balance shafts through 180� so that the weights face upwards and then remove them, exercising the utmost care to avoid damaging the inner bearing shells.
37. Remove the balance shafts complete with sprockets and bearing housings.
38. Remove the end plate.
NOTE: When dismantling bearing caps and shells, store them carefully and in order so that they can be reassembled in their original positions.
39. Remove any carbon deposits from the edges, swivel the engine into a convenient position and remove all big-end bearing caps.
40. Install protective collar tool No. 75 19 531, or equivalent, on the studs and press or carefully tap the pistons out of the cylinders.
41. Remove the main bearing caps and lift out the crankshaft
NOTE: Observe the utmost care when handling the perforated disc.
42. Remove the perforated disc.
43. Remove all the bearing shells for both the main bearings and big-end bearings.
- Also remove the two thrust washers from the No. 3 main bearing.
44. Remove the piston cooling nozzles.