Preliminary Work

→ 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.

1. Disassemble engine to crankcase → Disassembling engine down to crankcase .
2. Remove piston → Removing Pistons  .
3. Attach special tool retaining device 9607  to the gear carrier with two M10 x 25 hexagon-head bolts -Arrows-  .
   Fig 1: Locating Gear Carrier Bolts

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4. Unscrew cylinder-head screws with spacer sleeves 9613  .
5. Screw in retaining eyes on retaining device, lift gear carrier out of the crankcase half using a workshop crane or engine lifter and secure in a vice.
   Fig 2: Lifting Gear Carrier Out Of Crankcase

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6. Remove accessories on gear carrier.

   Gear Carrier Components Overview With Intermediate Shaft 

   Fig 3: Exploded View Of Gear Carrier With Intermediate Shaft

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   Item No.	Designation	Number	Removal	Fitting
   1	M6 x 40 fastening screw with captive washer	3		Tightening torque: 10 Nm (7.5 ftlb.)
   2	Guide rail	1	Visually inspect for scoring or damage and replace if necessary
   3	Snap ring	1		Replace
   4	Shim 10 x 16 x 1.2	1
   5	Tensioning rail	1
   5a	Lining for tensioning rail	1	Visually inspect for scoring or damage and replace if necessary
   6	Intermediate shaft	1	Check teeth for signs of damage
   7	Chain for camshaft driving mechanism, cylinder 1-3	1	Check for visible damage, replace if necessary
   8	Chain for camshaft driving mechanism, cylinder 4-6	1	Check for visible damage, replace if necessary
   9	Chain for intermediate shaft driving mechanism	1	Check for visible damage, replace if necessary
   10	Oil guide fastening screw (Torx, M6 x 16)	6		Replace micro-encapsulated screws
   11	Seal for oil guide	2		Replace
   12	Oil guide	1
   13	Gear carrier	1	Fit on retaining device 9607	Fit on retaining device 9607

7. Remove tensioning rail and guide rail. Unscrew three M6 x 40 hexagon-head bolts and remove tensioning rail -1-  . Remove circlip and washer -2-  , remove guide rail -3-  .
   Fig 4: Identifying Chain Guide And Intermediate Shaft

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8. Remove intermediate shaft with timing chains and place on a clean surface. Check timing chains and teeth on intermediate shaft for signs of damage, replace if necessary.
9. Remove oil guide on gear carrier. Unscrew six M6 x 16 Torx screws -1-  and remove guide with seals.
   Fig 5: Locating Oil Guide And Intermediate Shaft Screws

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