To Dismantle the Engine

Engine B235R

To Dismantle The Engine






1. Remove the starter motor.
2. 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 removal tool 87 92 616. Plug the gearbox with protective plug 87 92 244.
3. Remove the generator bracket and crankcase breather's oil trap complete with hoses.
4. Remove the intake manifold stay.
5. Undo the nut on the rear engine mounting.
6. Dismantle the leads to the oxygen sensor.





7. Detach the exhaust pipe from the turbocharger.
8. Lift the power train and roll away the table with the subframe. Remove the bracket, engine mounting and bolts lower, rear on the engine to the gearbox.





9. Fit holder 83 95 220 on the engine and lift the power train to floor stand 78 74 878.
10. Drain the engine oil.





11. Undo the bolts and lift away the gearbox. Use lifting cable 87 92 442.
12. Detach the oil filler pipe from its mounting.
13. Remove the bracket for the electric leads from the cylinder head.
14. Unplug all electric connectors between the intake manifold and engine.





15. Remove the boost pressure control valve and detach the hoses from the wastegate.
16. Remove the steering servo bracket with the lifting eye.
17. Remove the A/C compressor bracket.
18. Remove the turbo steady bar, disconnect the water and oil pipes and remove the turbocharger complete with exhaust manifold. If it does not come away easily, heat it carefully.





19. Remove the throttle body preheating hose.
20. Remove the bolts retaining the intake manifold. Lift it away from the power train.
21. Remove the thermostat housing's cover complete with thermostat.





22. Remove the water pump complete with filler pipe and the sleeve with the O-rings.
23. Remove the oil filter and the adapter housing.
24. Remove the protective cap and the crankshaft position sensor.





25. Align the O mark on the crankshaft pulley with the mark on the transmission casing.
26. Fit flywheel locking attachment 83 94 868 and remove the crankshaft pulley.
27. Dismantle the flywheel, pressure plate and clutch plate, and remove the flywheel locking attachment.





28. Remove the ignition discharge module.
29. Remove the spark plugs and remove the camshaft cover.





30. Remove the chain tensioner. First remove the plug, then use a 27 mm socket.
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 and then continue in reverse order to assembly. 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 filter.
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 point upward and remove them with great care so that the inner bearing bushings are not damaged.

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





41. Remove the end plate.

IMPORTANT: When dismantling bearing caps and shells, store them carefully and in the right order so that they can be reassembled in their original positions.

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 33 on 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: Observe the utmost care when handling the slotted ring.

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.