Disassembling Engine

Information 

Have a collection pan and some cloths ready before starting work on the engine block. Close off open hoses immediately after opening them using suitable stoppers. Residual fluid can leak out.

Information 

For many components, it is only necessary to partially disassemble the engine. The extent of disassembly depends on the damage and scope of repairs to be carried out.

When replacing the cylinder-head gasket, some add-on parts, such as the vacuum pump, injectors and exhaust manifolds, remain on the cylinder head. In this case, the cylinder head can be lifted off the crankcase with all add-on parts intact.

1. Remove drive belt.

   > 137819 REMOVING AND INSTALLING DRIVE BELT

2. Remove power-steering pump and air conditioning compressor if necessary.
3. Remove spark plugs.

   >WM, 287055 REMOVING AND INSTALLING SPARK PLUGS .

4. Remove tank vent line -3-  and engine ventilation lines -1 and 2-  .
   Fig 1: Ventilation Components Location - Naturally Aspirated Engines

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   Ventilation on naturally aspirated engines

   1	Engine ventilation line
   2	Oil mist separator line to intake-air distributor
   3	Tank ventilation
   4	Aluminium holder
   5	Aluminium screw (holder); see Chain housing cover

5. Remove oil mist separator.

   >WM, 105519 REMOVING AND INSTALLING OIL SEPARATOR 

6. Remove intake-air distributor.

   > 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR

7. Remove fuel distribution pipe.

   >WM, 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE

8. Remove high-pressure pump at cylinder 8.

   > 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP

9. Remove vacuum pump at cylinder 4. To do this, loosen the three screws. > Vacuum pump 

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   Vacuum pump

10. Detach and remove the coolant hose assembly -5-  . Remove coolant pipe -4-  .
    Fig 2: Coolant Return Components Location - Naturally Aspirated Engine

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    Coolant return on naturally aspirated engine

    1	Connection piece on generator
    2	Connection piece screw
    3	Screw, M6 x 20
    4	Coolant return line
    5	Coolant return hose assembly
    6	Holder
    7	M6 screw
    8	Clip

11. Remove water pump.

    > 195019 REMOVING AND INSTALLING COOLANT PUMP

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    Coolant pump

12. Remove vent line.
    1. 12.1 Unscrew fastening screws -1-  .
    2. 12.2 Unclip vent line -2-  from the cable duct and remove it -arrow-  .

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    Removing vent line

13. Remove heat protection panels on both sides.

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    Heat protection panels on V8 naturally aspirated engine

14. Remove the generator. Expose the peripheral equipment and unscrew the generator.
    1. 14.1 Remove support bracket (crash support) -10-  from the generator (two screws) -9-  .

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       Auxiliary units

    2. 14.2 Remove fastening screws on the generator -2 and 3-  .

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       Generator

    3. 14.3 Carefully remove generator and disconnect B+ cable. To do this, remove nut on the rear of the generator.
15. Remove high-pressure line -2-  from the cylinder head. To do this, remove union nut -4-  .

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    High-pressure pump on naturally aspirated engine

16. Disconnect the cable plug at the coolant regulator (thermostat insert) using pointed-nose pliers. Remove engine wire harness. For details, see > WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
    1. 16.1 Unscrew fastening screws.
    2. 16.2 Lift engine wire harness up and out -arrow- 

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    Loosening engine wire harness at the engine housing

17. Disconnect coolant pipe -1-  at the collection pipe -6-  . To do this, remove the screws -2-  .
    Fig 3: Coolant Guide Components Location

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    Coolant guide

    2	M6 screw
    3	Sealing ring
    4	Screw plug, M16 x 1.5
    5	M6 screw
    6	Coolant guide tube (collection pipe)
    7	Metal seal
    8	Stopper

18. Remove thermostat housing.
    1. 18.1 Pull out thermostat insert (coolant regulator) -5-  . Pull out thermostat insert (coolant regulator) using a solid electric cable. For a detailed description of how to remove the thermostat insert, see > 195819 REMOVING AND INSTALLING COOLANT REGULATOR
    2. 18.2 Detach thermostat housing and remove with the coolant pipe fitted.
    Fig 4: Thermostat Housing And Coolant Regulator Components Location

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    Thermostat housing and coolant regulator

    1	Thermostat housing
    2	Screw, M6 x 25
    3	Screw, M6 x 25; screwed to fuel high-pressure distributor pipe => see relevant article
    4	Seal for thermostat housing; replace
    5	Thermostat insert; including electric heating element

19. Remove metal pipe for coolant supply -2-  . Remove coolant hoses and metal pipe -5 and 6-  .
    Fig 5: Coolant Supply Components Location - Naturally Aspirated Engine

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    Coolant supply on naturally aspirated engine

    1	M6 screw; securing coolant line to collection pipe
    2	Coolant pipe
    3	Connection piece screw
    4	Connection piece on generator
    5	Coolant supply hose for oil/coolant heat exchanger
    6	Coolant supply hose to generator

20. Remove starter -1-  . To do this, remove screws -2-  .

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    Starter

21. Remove exhaust manifold on both sides. To do this, expose cable for oxygen sensor (lambda sensor).

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    Exhaust manifold on naturally aspirated engine (cylinders 1 to 4 shown)

22. Remove engine carrier with engine mountings on both sides. Then remove the brackets for the auxiliary units. > Left bracket for auxiliary units and engine mounting  > Right bracket for auxiliary units and engine mounting 

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    Left bracket for auxiliary units and engine mounting

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    Right bracket for auxiliary units and engine mounting

23. Remove belt tensioner and deflection rollers. To do this, carefully lever off the covers on the rollers and unscrew the components. -1, 2, 3, 4- 

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    Belt drive

24. Unscrew oil pressure sensor -3-  with adapter -1-  from the crankcase. To do this, remove the screws -4-  .

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    Oil pressure sensor and oil pressure measuring point

25. Remove both cylinder head covers (valve covers). > Bar ignition modules and valve covers, cylinder row 1 to 4  > Bar ignition modules and valve covers, cylinder bank 5 to 8 

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    Bar ignition modules and valve covers, cylinder row 1

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    Bar ignition modules and valve covers, cylinder bank 5 to 8

    WARNING: Danger of objects or loads falling down 

    • Risk of squashing or crushing 

      → Secure components to prevent them from falling down.

    Information 

    Support the engine at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block.

26. Loosen screw on vibration balancer by two turns -4 and 3-  . To do this, hold a counter-hold tool > 9679/1 - counter-hold tool at the vibration balancer with the help of a second worker. Support the counter-hold tool on the floor if necessary. A very high torque is required to loosen the screw (more than 800 Nm/592 ft lb.). A long 3/4-inch tool is the best tool to use for this. The engine should be supported to prevent it from tipping over.

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    Supporting engine (illustration shows V8 4.5-litre engine supported on assembly support)

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    Pulleys

27. Turn the crankshaft at the vibration balancer so that the staking bore of the vibration balancer is located approx. 45° degrees in front of the lower staking point on the chain housing cover. > Staking bore 45 degrees before TDC 

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    Staking bore 45 degrees before TDC

28. Remove chain tensioner for timing chain from the chain housing cover. -5- 

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    Chain tensioner

29. Loosen camshaft controller and sprockets on the four camshafts by 2 turns. Always counter at the hexagon on the components when doing this. > Sprocket  > Camshaft controller 

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    Sprocket

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    Camshaft controller

30. Remove vibration balancer.
31. Turn the engine around. The oil pan must be facing upwards.
32. Unscrew oil pan -1-  . To do this, remove all the screws -4-  . The inserted seal can be reused. It only needs to be replaced if damaged (cracked, worn down, hardened, etc.) or if it is leaking.

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    Oil pan

33. Detach and remove joint flange on the oil pressure control valve -2-  . Disconnect oil level sensor and remove by turning -5-  .

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    Oil guide housing with accessories

34. Remove all oil lines between the oil guide housing and oil pump. > Oil lines on naturally aspirated engine  > Oil lines, intake pipe on naturally aspirated engine 

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    Oil lines on naturally aspirated engine

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    Oil lines, intake pipe on naturally aspirated engine

35. Remove all screws between the oil guide housing and crankcase/chain housing cover -4-  . Don't forget the screws at the front -7-  .
    Fig 6: Oil Guide Housing Components Location

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    Oil guide housing with accessories

    1	Screw, M6 x 20
    2	Joint flange
    3	Sealing ring
    4	Oil guide housing to lower part of crankcase - aluminium screw
    5	Oil level sensor
    6	Oil level sensor to oil guide housing (steel screw)
    7	Timing-case cover to oil guide housing - aluminium screw

36. The oil guide housing is sealed with glue. To make it easier to remove, carefully lever off the oil guide housing between the outer flanges on the crankcase and the oil guide housing. > Removing oil guide housing  Loosen by tapping carefully with a plastic hammer if necessary. Remove the entire oil guide housing. Remove old sealing ring for the crankcase.

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    Removing oil guide housing

37. Remove joint flange on vibration balancer -1-  at the chain housing cover. To do this, remove screws -2 and 3-  .

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    Chain tensioner, joint flange

38. Remove all M6 and M8 screws on the chain housing cover > Chain housing cover  and lift off chain housing cover. Also remove all metal seals -2, 3, 4, 5-  .

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    Chain housing cover

    Fig 7: Chain Housing Cover Seals Components Location

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    Chain housing cover seals

    1	Chain housing cover
    2	Chain housing cover seal, outer right (fill openings with sealant, see 6)
    3	Inner chain housing cover seal
    4	Chain housing cover rib seal
    5	Chain housing cover seal, outer left (fill openings with sealant, see 6)
    6	Applying sealant to timing chain housing; Loctite 5900 (000.043.204.35 status 10/09)

39. Remove timing chain -1-  (mark rolling direction for re-installation using a felt-tip pen) from all the sprockets and place on a clean surface.

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    Timing chain and sprockets

40. Remove tensioning rail -4-  . Remove threaded peg -1-  if necessary.

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    Tensioning rail

41. Remove U-rail (guide rail) -4-  . To do this, remove four M8 screws -5-  .

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    Timing chain and sprockets

42. Carefully slacken the lower tensioning rail for the oil pump chain. Press the tensioning rail back with a small screwdriver until both staking holes between the tensioning rail and guide rail are aligned. > Oil pump tensioning rail 

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    Oil pump tensioning rail

43. Stake tensioning rail for oil pump chain through the hole in the guide rail using a suitable drill bit, drift punch or nail. This slackens the oil pump chain. > Staking tensioning rail for oil pump chain 

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    Staking tensioning rail for oil pump chain

44. Remove the guide rail -3-  . The guide rail is locked with -6-  .

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    Guide rail

45. If the sprockets and camshaft controllers are to be separated from the camshafts, now unscrew the loosened camshaft controllers and sprockets.
    Fig 8: Camshaft Adjustment Components Location

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    Camshaft adjustment

    1	Screw, M12 Tighten fully after setting timing.
    2	Camshaft controller with integrated hexagon for countering
    3	Camshaft control hydraulic valve
    4	Screw, M5 x 12

46. Slowly and uniformly loosen and then unscrew all M6 screws -3 and 5-  in the camshaft housings -2, 4 and 6-  . The housings are marked E for intake camshaft and A for outlet camshaft. The housings are numbered consecutively by cylinder. The housings are seated very securely in the cylinder head because of a dowel sleeve -1-  . Jiggle free using a pliers if necessary. Place on a marked, clean surface.

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    Camshaft mount, cylinders 5 to 8

47. Remove camshafts -3 and 6-  and place on a marked, clean surface.

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    Camshafts, cylinders 5 to 8

48. Remove valve lifters -1 and 2-  and place on a marked, clean surface in such a way that they cannot be mixed up.

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    Diagram showing how to set down lifters

49. Remove mounting saddle at the front -8-  . This hides the cylinder head screws underneath.
50. Remove front M8 screw securing the cylinder head of cylinders 1 to 4 to the crankcase. -3- 

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    Cylinder head 1 to 4

51. Turn the engine so that the cylinder head you want to remove is pointing straight upwards.
52. The injectors can now be removed easily if necessary. For details, see > WM, 244020 REMOVING AND INSTALLING FUEL INJECTORS
53. Remove cylinder head screws in the opposite order to the tightening sequence shown > Tightening sequence for cylinder head  . Remove cylinder head.
    Fig 9: Cylinder Head Screws Tightening Sequence

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    Tightening sequence for cylinder head

54. Remove cylinder head gasket.
55. Remove cylinder head for cylinders 5 to 8 in the same way.
56. Turn the engine around. The oil pump must be facing upwards.
57. Remove chain cover for oil pump -9-  . To do this, remove the screws -10-  .

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    Oil pump on naturally aspirated engine

58. Remove drive pinion for oil pump. Screw is tightened beyond the elastic limit. Use a screwdriver to counter at the oil pump through the bore in the drive pinion. > Countering oil pump pinion 

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    Countering oil pump pinion

59. Remove oil pump pinion with chain and crankshaft pinion. > Oil pump chain 

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    Oil pump chain

60. Unscrew oil pump -1-  . To do this, remove screws -8-  . Pull oil pump out at the point where the pipe engages at the rear with the oil plate. When doing so, make sure that the locking lug does not break off. Swivel oil pump up and out.
61. Unscrew oil plate/oil guide.

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    Oil guide (oil plate)

62. Remove lower part of crankcase. First unscrew the four M8 screws on the output side -8 and 9-  .

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    Lower part of crankcase

    1. 62.1 Unscrew and remove outer M8 cross bolt connection in reverse order to the tightening sequence. Always use new aluminium screws.
       Fig 10: Lower Part And Upper Part Of Crankcase Screws Tightening Sequence (Cross Bolt Connection)

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       Tightening sequence for securing lower part of crankcase to upper part of crankcase (cross bolt connection)

    2. 62.2 Unscrew M10 and M11 thrust-bearing screws in the opposite order to the tightening sequence. Start with the outer M10 screws first.
       Fig 11: Thrust-Bearing Screws Tightening Sequence

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       Tightening sequence for thrust-bearing screws

    3. 62.3 Lift off lower part of crankcase. Get a second person to help if necessary. Remove old sealing ring for the upper part of the crankcase. Remove bearing shells if necessary and mark them.
63. Secure the crankshaft at the centre using a holding bridge > 9677/1 - holding bridge. Tighten screws slightly. -1- 

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    Crankshaft secured

64. Loosen connecting rod bolts -6-  and take off connecting rod caps -5-  . Push piston in question out of the crankcase using a wooden rod. Hold it in your other hand or get another person to help. Fit connecting rod cap hand-tight to the connecting rod again using the old screws and set down after marking according to the relevant cylinder. The connecting rod bolts must be replaced with new ones during re-installation. The connecting rods are cracked and the connecting rod code is facing the exhaust side. The combustion chamber recess on the piston is facing the injector.

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    Piston, connecting rod

65. Remove all pistons in the same way.
66. (If you have not already done so) turn the engine so that the crankshaft is at the top.
    CAUTION: Heavy components 

    • Risk of squashing 

      → Wear personal protective gear.

      → Get someone to help if necessary.

67. After removing all pistons, remove the crankshaft -1-  , remove the > 9677/1 - holding bridge and place the crankshaft -1-  on a clean surface.

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    Crankshaft

68. Remove all bearing shells -5 and 6-  and thrust washers -4-  if necessary. Mark the bearing shells and set them down.
69. Remove oil spray jets -6-  . To do this, loosen screws -7-  .

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    Upper part of crankcase

70. Remove coolant guide -6-  . Remove seals -7-  .

Fig 12: Coolant Guide Components Location

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Coolant guide

Information 

Have a collection pan and some cloths ready before starting work on the engine block. Close off open hoses immediately after opening them using suitable stoppers. Residual fluid can leak out.

Information 

For many components, it is only necessary to partially disassemble the engine. The extent of disassembly depends on the damage and scope of repairs to be carried out.

When replacing the cylinder-head gasket, some add-on parts, such as the vacuum pump, injectors and exhaust manifolds, remain on the cylinder head. In this case, the cylinder head can be lifted off the crankcase with all add-on parts intact.

1. Remove drive belt.

   > 137819 REMOVING AND INSTALLING DRIVE BELT

2. Remove power-steering pump and air conditioning compressor if necessary.
3. Remove spark plugs.

   > WM, 287055 REMOVING AND INSTALLING SPARK PLUGS

4. Remove tank vent line and engine ventilation lines. The full-throttle ventilation system on turbo engines is designed with one-way plug connections to the turbocharger intake manifold.
   Fig 13: Ventilation Components Location - Turbo Engines

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   Ventilation on turbo engines

   1	Engine ventilation line
   2	Full-throttle ventilation check valve with lines secured and one-way coupling for turbo intake manifold
   3	Tank ventilation
   4	Aluminium holder
   5	Aluminium screw (holder); see Chain housing cover
   6	Belt tensioner
   7	Holder
   8	Fastening screw; see Belt drive

5. Remove oil mist separator.

   > WM, 105519 REMOVING AND INSTALLING OIL SEPARATOR 

6. Remove intake-air distributor.

   > 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR

7. Remove fuel distribution pipe.

   > WM, 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE

8. Remove high-pressure pump at cylinder 8.

   > 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP

9. Remove vacuum pump -1-  at cylinder 4. To do this, loosen the three screws -2-  .

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   Vacuum pump

10. Remove high-pressure line from cylinder head -2-  . To do this, remove the union nut -4-  .

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    High-pressure pump on turbo engine, 6-piston pump

11. Remove coolant pipe -1-  . Disconnect coolant hose from the generator -4 and 5-  .

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    Coolant supply line, turbo engine

12. Detach and remove the coolant hose assembly -5-  . Remove coolant pipe -4-  .
    Fig 14: Coolant Return Components Location - Turbo Engine

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    Coolant return on turbo engine

    1	Connection piece on generator
    2	Connection piece screw
    3	Screw, M6 x 20
    4	Coolant return line
    5	Coolant return hose assembly
    6	Holder
    7	M6 screw
    8	Clip

13. Remove water pump.

    > 195019 REMOVING AND INSTALLING COOLANT PUMP

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    Coolant pump

14. Remove vent line.
    1. 14.1 Undo fastening screws -1-  .
    2. 14.2 Unclip vent line -2-  from the cable duct and remove it -arrow-  .

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    Removing vent line

15. Remove the engine carrier. Remove engine mountings on both sides and brackets for auxiliary units only after removing the turbochargers. > Left bracket for auxiliary units and engine mounting  > Right bracket for auxiliary units and engine mounting 

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    Left bracket for auxiliary units and engine mounting

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    Right bracket for auxiliary units and engine mounting

16. Remove the generator. Expose the peripheral equipment and unscrew the generator.
    1. 16.1 Remove support bracket (crash support) -10-  from the generator (two screws) -9-  .

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       Auxiliary units

    2. 16.2 Remove fastening screws on the generator -2 and 3-  .

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       Generator

    3. 16.3 Carefully remove generator and disconnect B+ cable. To do this, remove nut on the rear of the generator.
17. Remove wastegate lines and boost-pressure control lines > Boost pressure and wastegate  > Boost pressure and wastegate 2  . Mark lines and place aside in order.

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    Boost pressure and wastegate

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    Boost pressure and wastegate 2

18. Remove engine wire harness. Disconnect cable plug for the engine wire harness at the coolant regulator (thermostat insert) using pointed-nose pliers. For details, see > WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE
    1. 18.1 Unscrew fastening screws.
    2. 18.2 Lift engine wire harness up and out -arrow- 

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    Loosening engine wire harness at the engine housing

19. Disconnect coolant pipe at the collection pipe. To do this, remove the screws -2-  .
    Fig 15: Coolant Guide Components Location

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    Coolant guide

    2	M6 screw
    3	Sealing ring
    4	Screw plug, M16 x 1.5
    5	M6 screw
    6	Coolant guide tube (collection pipe)
    7	Metal seal
    8	Stopper

20. Remove thermostat housing.
    1. 20.1 Pull out thermostat insert (coolant regulator) -5-  . Pull out thermostat insert using a strong cable. For a detailed description of how to remove the thermostat insert, see > 195819 REMOVING AND INSTALLING COOLANT REGULATOR
    2. 20.2 Detach thermostat housing and remove with the coolant pipe fitted.
    Fig 16: Thermostat Housing And Coolant Regulator Components Location

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    Thermostat housing and coolant regulator

    1	Thermostat housing
    2	Screw, M6 x 25
    3	Screw, M6 x 25; screwed to fuel high-pressure distributor pipe => see relevant article
    4	Seal for thermostat housing; replace
    5	Thermostat insert; including electric heating element

21. Remove starter -1-  . To do this, remove screws -2-  .

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    Starter

22. Remove the two turbochargers with lines connected. For details, see > 213019 REMOVING AND INSTALLING TURBOCHARGER
23. Remove the exhaust manifold by loosening the nuts.

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    Exhaust manifold on turbo engine

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    Exhaust manifold on turbo engine

24. Disconnect PCV line on the engine > Positive crankcase ventilation (PCV) on turbo engine  . Disconnect the line at the crankcase to do this.

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    Positive crankcase ventilation (PCV) on turbo engine

25. Remove belt tensioner and deflection rollers. To do this, carefully lever off the covers on the rollers and unscrew the components. -1, 2, 3, 4- 

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    Belt drive

26. Unscrew oil pressure sensor -3-  with adapter -1-  from the crankcase. To do this, remove the screws -4-  .

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    Oil pressure sensor and oil pressure measuring point

27. Remove both cylinder head covers (valve covers). > Bar ignition modules and valve covers, cylinder row 1 to 4  > Bar ignition modules and valve covers, cylinder bank 5 to 8 

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    Bar ignition modules and valve covers, cylinder row 1

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    Bar ignition modules and valve covers, cylinder bank 5 to 8

    WARNING: Danger of objects or loads falling down 

    • Risk of squashing or crushing 

      → Secure components to prevent them from falling down.

    Information 

    Support the engine at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block.

28. Loosen screw on vibration balancer by two turns -4 and 3-  . To do this, hold a counter-hold tool > 9679/1 - counter-hold tool at the vibration balancer with the help of a second worker. Support the counter-hold tool on the floor if necessary. A very high torque is required to loosen the screw (more than 800 Nm/592 ft lb.). A long 3/4-inch tool is the best tool to use for this. The engine should be supported to prevent it from tipping over.

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    Supporting engine (illustration shows V8 4.5-litre engine supported on assembly support)

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    Pulleys

29. Turn the crankshaft at the vibration balancer so that the staking bore of the vibration balancer is located approx. 45° degrees in front of the lower staking point on the chain housing cover. > Staking bore 45 degrees before TDC 

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    Staking bore 45 degrees before TDC

30. Remove chain tensioner for timing chain from the chain housing cover. -5- 

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    Chain tensioner

31. Loosen camshaft controller and sprockets on the four camshafts by 2 turns. Always counter at the hexagon on the components when doing this. > Sprocket  > Camshaft controller 

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    Sprocket

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    Camshaft controller

32. Remove vibration balancer.
33. Turn the engine around. The oil pan must be facing upwards.
34. Unscrew oil pan -1-  . To do this, remove all screws -4-  . The inserted seal can be reused. It only needs to be replaced if damaged (cracked, worn down, hardened, etc.) or if it is leaking.

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    Oil pan

35. Detach and remove joint flange on the oil pressure control valve -2-  . Disconnect oil level sensor and remove by turning -5-  .

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    Oil guide housing with accessories

36. Remove all oil lines between the oil guide housing and oil pump. > Oil lines on turbo engine  > Oil lines, intake pipe on turbo engine 

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    Oil lines on turbo engine

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    Oil lines, intake pipe on turbo engine

37. Remove all screws between the oil guide housing and crankcase/chain housing cover -4-  . Don't forget the screws at the front -7-  .
    Fig 17: Oil Guide Housing Components Location

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    Oil guide housing with accessories

    1	Screw, M6 x 20
    2	Joint flange
    3	Sealing ring
    4	Oil guide housing to lower part of crankcase - aluminium screw
    5	Oil level sensor
    6	Oil level sensor to oil guide housing (steel screw)
    7	Timing-case cover to oil guide housing - aluminium screw

38. The oil guide housing is sealed with glue. To make it easier to remove, carefully lever off the oil guide housing between the outer flanges on the crankcase and the oil guide housing. > Removing oil guide housing  Loosen by tapping carefully with a plastic hammer if necessary. Remove the entire oil guide housing. Remove old sealing ring.

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    Removing oil guide housing

39. Remove joint flange on vibration balancer -1-  at the chain housing cover. To do this, remove screws -2 and 3-  .

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    Chain tensioner, joint flange

40. Remove all M6 and M8 screws on the chain housing cover > Chain housing cover  and lift off chain housing cover. Also remove all the metal seals. > Chain housing cover seals 

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    Chain housing c

    Fig 18: Chain Housing Cover Seals Components Location

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    Chain housing cover seals

    1	Chain housing cover
    2	Chain housing cover seal, outer right (fill openings with sealant, see 6)
    3	Inner chain housing cover seal
    4	Chain housing cover rib seal
    5	Chain housing cover seal, outer left (fill openings with sealant, see 6)
    6	Applying sealant to timing chain housing; Loctite 5900 (000.043.204.35 status 10/09)

41. Remove timing chain -1-  (mark rolling direction for re-installation using a felt-tip pen) from all the sprockets and place on a clean surface.

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    Timing chain and sprockets

42. Remove tensioning rail -4-  . Remove threaded peg -1-  if necessary.

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    Tensioning rail

43. Remove U-rail (guide rail) -4-  . To do this, remove four M8 screws -5-  .

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    Timing chain and sprockets

44. Carefully slacken the lower tensioning rail for the oil pump chain. Press the tensioning rail back with a small screwdriver until both staking holes between the tensioning rail and guide rail are aligned. > Oil pump tensioning rail 

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    Oil pump tensioning rail

45. Stake tensioning rail for oil pump chain through the hole in the guide rail using a suitable drill bit, drift punch or nail. This slackens the oil pump chain. > Staking tensioning rail for oil pump chain 

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    Staking tensioning rail for oil pump chain

46. Remove guide rail -3-  . Guide rail is locked with -6-  .

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    Guide rail

47. If the sprockets and camshaft controllers are to be separated from the camshafts, now unscrew the loosened camshaft controllers and sprockets.
    Fig 19: Camshaft Adjustment Components Location

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    Camshaft adjustment

    1	Screw, M12 Tighten fully after setting timing.
    2	Camshaft controller with integrated hexagon for countering
    3	Camshaft control hydraulic valve
    4	Screw, M5 x 12

48. Slowly and uniformly loosen and then unscrew all M6 screws -3 and 5-  in the camshaft housings -2, 4 and 6-  . The bearing covers are marked E for intake camshaft and A for outlet camshaft. The bearing covers are numbered consecutively by cylinder. The bearing covers are seated very securely in the cylinder head because of a dowel sleeve -1-  . Jiggle free using a pliers if necessary. Place on a marked, clean surface.

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    Camshaft mount, cylinders 5 to 8

49. Remove camshafts -3 and 6-  and place on a marked, clean surface.

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    Camshafts, cylinders 5 to 8

50. Remove valve lifters -1 and 2-  and place on a marked, clean surface in such a way that they cannot be mixed up.

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    Diagram showing how to set down lifters

51. Remove mounting saddle at the front -8-  . This hides the cylinder head screws underneath.
52. Remove front M8 screw securing the cylinder head of cylinders 1 to 4 to the crankcase. -3- 

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    Cylinder head 1 to 4

53. Turn the engine so that the cylinder head you want to remove is pointing straight upwards.
54. The injectors can now be removed easily if necessary. For details, see > WM, 244020 REMOVING AND INSTALLING FUEL INJECTORS
55. Remove cylinder head screws in the opposite order to the tightening sequence shown > Tightening sequence for cylinder head  . Remove cylinder head.
    Fig 20: Cylinder Head Screws Tightening Sequence

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    Tightening sequence for cylinder head

56. Remove cylinder head gasket.
57. Remove cylinder head for cylinders 5 to 8 in the same way.
58. Turn the engine around. The oil pump must be facing upwards.
59. Remove chain cover for oil pump -9-  . To do this, remove screws -10-  .

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    Oil pump on turbo engine with oil extraction stage

60. Remove drive pinion for oil pump. Screw is tightened beyond the elastic limit. Use a screwdriver to counter at the oil pump through the bore in the drive pinion. > Countering oil pump pinion 

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    Countering oil pump pinion

61. Remove oil pump pinion with chain and crankshaft pinion. > Oil pump chain 

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    Oil pump chain

62. Unscrew oil pump -1-  . To do this, remove screws -8-  . Pull oil pump out at the point where the pipe engages at the rear with the oil plate. When doing so, make sure that the locking lug does not break off. Swivel oil pump up and out.
63. Unscrew oil plate/oil guide.

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    Oil guide (oil plate)

64. Remove lower part of crankcase.

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    Lower part of crankcase

    1. 64.1 First unscrew the four M8 screws on the output side. -8 and 9- 
    2. 64.2 Unscrew and remove outer M8 cross bolt connection in reverse order to the tightening sequence.
       Fig 21: Lower Part And Upper Part Of Crankcase Screws Tightening Sequence (Cross Bolt Connection)

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       Tightening sequence for securing lower part of crankcase to upper part of crankcase (cross bolt connection)

    3. 64.3 Unscrew M10 and M11 thrust-bearing screws in the opposite order to the tightening sequence. Start with the outer M10 screws first.
       Fig 22: Thrust-Bearing Screws Tightening Sequence

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       Tightening sequence for thrust-bearing screws

    4. 64.4 Lift off lower part of crankcase. Get a second person to help if necessary. Remove old sealing ring. Remove bearing shells if necessary and mark them.
65. Secure crankshaft at the centre using a holding bridge > 9677/1 - holding bridge. Tighten screws slightly. -1- 

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    Crankshaft secured

66. Loosen connecting rod bolts -6-  and take off connecting rod caps -5-  . Push piston in question out of the crankcase using a wooden rod. Hold it in your other hand or get another person to help. Fit connecting rod cap hand-tight to the connecting rod again using the old screws and set down after marking according to the relevant cylinder. The connecting rod bolts must be replaced with new ones during re-installation. The connecting rods are cracked and the connecting rod code is facing the exhaust side. The combustion chamber recess on the piston is facing the injector.

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    Piston, connecting rod

67. Remove all pistons in the same way.
68. (If you have not already done so) turn the engine so that the crankshaft is at the top.
    WARNING: Danger of objects or loads falling down 

    • Risk of squashing or crushing 

      → Secure components to prevent them from falling down.

    CAUTION: Heavy components 

    • Risk of squashing 

      → Wear personal protective gear.

      → Get someone to help if necessary.

69. After removing all pistons, remove the crankshaft -1-  , remove the > 9677/1 - holding bridge and place the crankshaft -1-  on a clean surface.

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    Crankshaft

70. Remove all bearing shells -5 and 6-  and thrust washers -4-  if necessary. Mark the bearing shells and set them down.
71. Remove oil spray jets -6-  . To do this, loosen screws -7-  .

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    Upper part of crankcase

72. Remove coolant guide -6-  . Remove seals -7-  .

Fig 23: Coolant Guide Components Location

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Coolant guide