Disassembling Engine

→ Since the bucket tappets have been run in the fitting bores, do not interchange them.

→ Absolute cleanliness is essential.

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, many components, such as the vacuum pump, injectors and exhaust manifolds, remain on the cylinder head. In this case, the cylinder head can be lifted from the crankcase with all components 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. → 287020 REMOVING AND FITTING SPARK PLUGS
4. Remove tank vent line -3-  and engine ventilation lines -1 and 2-  .
   1. Engine ventilation line
   2. Oil mist separator line to intake-air distributor
   3. Tank ventilation
   4. Aluminum holder
   5. Aluminum screw (holder); see Fig 35Timing-case cover
   Fig 1: Identifying Engine Ventilation Line - Naturally Aspirated Engines
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5. Remove oil mist separator. → 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR 
6. Remove intake-air distributor. → 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
7. Remove fuel distribution pipe. → 243019 REMOVING AND INSTALLING FUEL DISTRIBUTION 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 
   Fig 2: Identifying Vacuum Pump Screws

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10. Detach and remove the coolant hose assembly -5-  . Remove coolant pipe -4-  .
    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
    Fig 3: Identifying Coolant Return Line - Naturally Aspirated Engine
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11. Remove water pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
    Fig 4: Identifying Coolant Pump Screws

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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-  .
       Fig 5: Removing Vent Line

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13. Remove heat protection panels on both sides.
    Fig 6: Locating Heat Protection Panels - V8 Naturally Aspirated Engine

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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-  .
       Fig 7: Identifying Engine Auxiliary Units Components

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    2. 14.2. Remove fastening screws on the generator -2 and 3-  .
       Fig 8: Identifying Generator Screws

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    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-  .
    Fig 9: Identifying High-Pressure Pump Components - Naturally Aspirated Engine

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16. Disconnect the cable plug at the coolant regulator (thermostat insert) using pointed-nose pliers. Remove engine wire harness. For details, see → 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- 
       Fig 10: Loosening Engine Wire Harness

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17. Disconnect coolant pipe -1-  at the collection pipe -6-  . To do this, remove the screws -2-  .
    Fig 11: Identifying Coolant Guide Screws

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    1. 2  - M6 screw
    2. 3  - Sealing ring
    3. 4  - Screw plug, M16 x 1.5
    4. 5  - M6 screw
    5. 6  - Coolant guide tube (collection pipe)
    6. 7  - Metal seal
    7. 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.
       1. Thermostat housing
       2. Screw, M6 x 25
       3. Screw, M6 x 25; screwed to fuel high-pressure distribution pipe.
       4. Seal for thermostat housing; replace
       5. Thermostat insert; including electric heating element
       Fig 12: Identifying Thermostat Housing And Coolant Regulator Screws

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19. Remove metal pipe for coolant supply -2-  . Remove coolant hoses and metal pipe -5 and 6-  .
    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
    Fig 13: Identifying Coolant Supply Line - Naturally Aspirated Engine
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20. Remove starter -1-  . To do this, remove the screws -2-  .
    Fig 14: Identifying Starter Screws

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21. Remove exhaust manifold on both sides. To do this, expose cable for oxygen sensor (lambda sensor).
    Fig 15: Locating Exhaust Manifold Seal-Naturally Aspirated Engine (Cylinders 1 To 4)

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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 
    Fig 16: Identifying Auxiliary Units And Engine Mounting Left Bracket

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    Fig 17: Removing Auxiliary Units And Engine Mounting Right Bracket

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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- 
    Fig 18: Identifying Engine Drive Belt

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24. Unscrew oil pressure sensor -3-  with adapter -1-  from the crankcase. To do this, remove the screws -4-  .
    Fig 19: Identifying Oil Pressure Sensor, Adapter And Screws

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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 
    Fig 20: Identifying Bar Ignition Modules And Valve Covers

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    Fig 21: Identifying Bar Ignition Modules And Valve Covers

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    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 brace brace 9679/1  at the vibration balancer with the help of a second worker. Support the brace on the floor if necessary. A very high torque is required to loosen the screw (more than 800 Nm/592 ftlb.). 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.
    Fig 22: Supporting Engine

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    Fig 23: Identifying Engine Pulleys

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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 timing-case cover. → Staking bore 45 degrees before TDC 
    Fig 24: Removing Chain Tensioner

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28. Remove chain tensioner for timing chain from the timing-case cover. -5- 
    Fig 25: Identifying Crankshaft Bore Position

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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 
    Fig 26: Loosening Camshaft Controller And Sprockets

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    Fig 27: Loosening Camshaft Controller

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30. Rem↓ove 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.
    Fig 28: Identifying Oil Pan Screws

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33. Detach and remove joint flange on the oil pressure control valve -2-  . Disconnect oil level sensor and remove by turning -5-  .
    Fig 29: Identifying Oil Guide Housing With Accessories

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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 
    Fig 30: Identifying Oil Lines - Naturally Aspirated Engine

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    Fig 31: Identifying Oil Lines Intake Pipe - Naturally Aspirated Engine

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35. Remove all screws between the oil guide housing and crankcase/timing-case cover -4-  . Don't forget the screws at the front -7-  .
    1. Screw, M6 x 20
    2. Joint flange
    3. Sealing ring
    4. Oil guide housing to lower part of crankcase - aluminum screw 
    5. Oil level sensor
    6. Oil level sensor to oil guide housing (steel screw)
    7. Timing-case cover to oil guide housing - aluminum screw 
    Fig 32: Identifying Oil Guide Housing With Accessories

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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.
    Fig 33: Removing Oil Guide Housing

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37. Remove joint flange on vibration balancer -1-  at the timing-case cover. To do this, remove the screws -2 and 3-  .
    Fig 34: Identifying Chain Tensioner Screws

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38. Remove all M6 and M8 screws on the timing-case cover → Timing-case cover  and lift off the timing-case cover. Also remove all the metal seals -2, 3, 4, 5-  .
    Fig 35: Identifying Timing-Case Cover Screws

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    1. Timing-case cover
    2. Timing-case cover seal, outer right (fill openings with sealant, see  6)
    3. Timing-case cover seal, inner
    4. Timing-case cover seal, rib
    5. Timing-case 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)
    Fig 36: Identifying Timing-Case Cover Seals

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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.
    Fig 37: Identifying Timing Chain And Sprockets

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40. Remove tensioning rail -4-  . Remove threaded peg -1-  if necessary.
    Fig 38: Identifying Tensioning Rail

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41. Remove U-rail (guide rail) -4-  . To do this, remove four M8 screws -5-  .
    Fig 39: Identifying Timing Chain And Sprockets Screws

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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 
    Fig 40: Pressing Oil Pump Tensioning Rail

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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 
    Fig 41: Installing Oil Pump Chain Tensioning Rail

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44. Remove the guide rail -3-  . The guide rail is locked with -6-  .
    Fig 42: Removing Guide Rail

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45. If the sprockets and camshaft controllers are to be separated from the camshafts, now unscrew the loosened camshaft controllers and sprockets.
    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
    Fig 43: Identifying Camshaft Adjustment Screws And Camshaft Control Hydraulic Valve

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46. 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.
    Fig 44: Identifying Camshaft Mount Screws (Cylinders 5 To 8)

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47. Remove camshafts -3 and 6-  and place on a marked, clean surface.
    Fig 45: Identifying Camshafts (Cylinders 5 To 8)

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48. Remove valve lifters -1 and 2-  and place on a marked, clean surface in such a way that they cannot be mixed up.
    Fig 46: Valve Lifters Information Diagram

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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- 
    Fig 47: Identifying Cylinder Head

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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 → 244019 REMOVING AND INSTALLING FUEL INJECTOR
53. Remove cylinder head screws in the opposite order to the tightening sequence shown → Tightening sequence for cylinder head below  . Remove cylinder head.
    Fig 48: Cylinder Head Screws Tightening Sequence

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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-  .
    Fig 49: Identifying Oil Pump Screws - Naturally Aspirated Engine

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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 
    Fig 50: Turning Oil Pump Pinion

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59. Remove oil pump pinion with chain and crankshaft pinion. → Oil pump chain 
    Fig 51: Removing Oil Pump Chain

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60. Unscrew oil pump -1-  . To do this, remove the 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.
    Fig 52: Identifying Engine Oil Guide (Oil Plate)

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62. Remove lower part of crankcase. First unscrew the four M8 screws on the output side -8 and 9-  .
    Fig 53: Identifying Crankcase Lower Part

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    1. 62.1. Unscrew outer M8 cross bolt connection in the opposite order to the tightening sequence. Always use new aluminum screws.
       Fig 54: Crankcase Screws Tightening Sequence

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    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 55: Thrust-Bearing Screws Tightening Sequence

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    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 center using a holding bridge holding bridge 9677/1  . Tighten screws slightly. -1- 
    Fig 56: Identifying Crankshaft Screws

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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.
    Fig 57: Identifying Piston And Connecting Rod

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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 the pistons, remove the crankshaft -1-  (remove holding bridge) and place on a clean surface.
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 the screws -7-  .
    Fig 58: Identifying Crankshaft

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    Fig 59: Identifying Crankcase Upper Part

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70. Remove coolant guide -6-  . Remove seals -7-  .
    1. 2  - M6 screw
    2. 3  - Sealing ring
    3. 4  - Screw plug, M16 x 1.5
    4. 5  - M6 screw
    5. 6  - Coolant guide tube (collection pipe)
    6. 7  - Metal seal
    7. 8  - Stopper
    Fig 60: Identifying Coolant Guide Screws And Sealing Ring

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