To Dismantle the Engine

Engine Block B235R, B205L/R

To Dismantle the Engine





1. Unplug the connectors on the wiring harness.
2. Remove the bracket and wiring harness as one unit.





3. Remove the starter motor.
4. Remove the generator and belt tensioner. Remove the support bearing bracket with intermediate shaft and the inboard drive shaft joint. Remove the left-hand drive shaft. Use 87 92 616 Removal tool, drive shafts. Plug the gearbox with 87 92 244 Protective plugs, F25 drive shaft hole
5. Remove the generator bracket and crankcase breather's oil trap complete with hoses.
6. Remove the intake manifold stay.
7. Undo the nut on the rear engine mounting.





8. Fit 83 95 220 Holder, 4-cyl engine to the engine and lift over the power train to 78 74 878 Floor stand.
9. Lift the power train and roll away the table with the subframe.
10. Undo the bolts and lift aside the gearbox. Use 87 92 442 Lifting cable.
11. Detach the oil filler pipe from its mounting.





12. Remove the steering servo bracket with the lifting eye.
13. Remove the A/C compressor bracket.
14. Remove the turbocharger steady bar, disconnect the air, coolant and oil pipes and remove the turbocharger complete with exhaust manifold. If it does not come away easily, heat it carefully.





15. Remove the fuel rail.
16. (B235R) Remove the rear lifting eye.
17. Remove the bolts retaining the intake manifold.
Lift away the pipe from the power train.
18. Remove the pipe leading to the water pump.
19. Remove the thermostat housing's cover complete with thermostat.





20. Remove the crankshaft position sensor and protective cap.
21. Remove the coolant pump complete with filler pipe and the sleeve with the O-rings.
22. Remove the oil filter adapter housing.





23. Align the O mark on the crankshaft pulley with the mark on the transmission casing.
24. Fit 83 94 868 Flywheel locking attachment and remove the crankshaft pulley.
25. Remove the pressure plate, clutch plate and flywheel. Remove the flywheel locking attachment.





26. Remove the banjo pipe leading to the intake manifold.
27. Remove the hose for crankcase ventilation.
28. Remove the ignition discharge module.
29. Remove the spark plugs and remove the camshaft cover.





30. Remove the belt tensioner. First, remove the plug, then use a 27 mm socket to remove the tensioner. Measure and make a note of the length of the chain tensioner.
31. Remove the camshaft sprockets, holding each camshaft steady with a spanner applied to the end of it.
32. Fit a rubber band round the chain guides and remove the cylinder head. Start with the bolts in the timing cover. Collect the bolts with a magnet.





33. Turn the engine to a suitable working position and remove the oil sump and the pipe to the oil adapter.
34. Remove the oil pump and timing cover.





35. Remove the top chain guide and chain tensioner for the balancer-shaft chain.
36. Remove the idler sprocket and balancer shaft chain.
37. Remove the oil pump driver and sprocket from the crankshaft.
38. Remove the balancer-shaft and camshaft chain guides.
39. Remove the timing chain guard and remove the chain complete with sprocket.

Important: Turn the balancer shafts 180°, so that the weights are pointing up. Remove them carefully so the inner bearing bushes are not damaged.

40. Remove the balancer shafts complete with sprockets and bearing housings.





41. Remove the end plate.

Important: When removing caps and bearing races, make sure that parts are kept in such a way that they can be refitted with the right parts in the right place.

42. Remove any carbon deposits from the edges, turn the engine into a convenient position and remove all big-end bearing caps.

Note: Use a 12 point 14 mm socket.

43. Fit Protective sleeve 75 19 531 onto the studs and press or carefully tap the pistons out of the cylinders.
44. Remove all main bearing caps and lift out the crankshaft.

Important: The field rotor flange must be treated very carefully. Make sure the main bearing adjustment sleeves are unscrewed, if they are not fastened.

45. Remove the slotted ring.
46. Remove all the bearing shells for both the main bearings and big-end bearings. Also remove the two thrust washers from main bearing no. 3.
47. Remove the piston cooling nozzles.