Disassembling V6 DFI Engine

arrows  - Belt tensioner

Fig 1: Locating Belt Tensioner Bolts

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Fig 2: Exploded View Of Unit Carrier

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1. Belt tensioner
2. Cheese head bolt on belt tensioner
3. Unit carrier
4. Fit bolt for unit carrier
5. Cheese head bolt for unit carrier
6. Dowel sleeve for unit carrier
7. Deflection roller with fastening screw
8. Drive belt (poly-rib belt)
9. Generator
10. Coolant pump pulley
11. Drive wheel for air conditioning compressor
12. Power-steering pump pulley
13. Crankshaft vibration damper

arrows  - Oval-head screws for pulley (coolant pump)

Fig 3: Locating Coolant Pump And Screws

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1. 8.1. Remove coolant pump pulley if necessary.

Fig 4: Identifying Coolant Pump Holed And Coolant Hoses

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1. Sheetmetal holder
2. Fastening screws for coolant pump holder
3. Coolant hose
4. Coolant hose
5. Coolant hose

1. 9.1. Unscrew fastening screws -2-  .
2. 9.2. Pull off cable plugs and remove coolant hoses -3, 4, 5-  .
3. 9.3. Remove additional coolant pump with sheetmetal holder -1-  .

arrows  - Fastening nuts for exhaust manifold

Fig 5: Locating Exhaust Manifold

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Fig 6: Identifying Fuel Distribution Pipe

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1. Fuel line (low-pressure)
2. Cheese head bolts for fuel distribution pipe
3. Fuel injectors

Fig 7: Identifying Thermostat Housing, Spring Band Clamp And Coolant Hose

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1. Thermostat housing
2. Spring band clamp
3. Coolant hose

1. 13.1. Loosen the spring band clamp -2-  .
2. 13.2. Pull thermostat housing -1-  completely out of the cylinder block.

1. 15.1. Remove dual-mass flywheel on vehicles with manual transmission. → Removing Flywheel (Dual-Mass Flywheel)
2. 15.2. Remove drive plate on vehicles with automatic transmission. → 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE CONVERTER

Information 

Removal of chain tensioner 

• Press the bottom chain tensioner together during removal because otherwise it will push out due to spring tensioning. Secure chain tensioner with a tie-wrap in tensioned state. 

1. 20.1. Remove camshaft controllers. → WM 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER ON V6 DFI ENGINES

Fig 8: Overview Of Cylinder Head On V6 DFI Engine

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1. Intake camshaft
2. Camshaft bearing cover
3. Outlet camshaft
4. Hexagon nut on camshaft bearing cover
5. Sealing rings (40 x 1.5)
6. Timing chain housing
7. Oval-head screw on timing chain housing
8. Outlet camshaft controller (marking 32 A)
9. Intake camshaft controller (marking 24 E)
10. Hexagon-head bolts on camshaft controllers
11. Cylinder head height (min. height a=139.9 mm)
12. Drive gear wheel for high-pressure pump
13. Bearing shaft
14. Valves
15. Dowel sleeve
16. Cylinder head
17. Pump tappet
18. Support element
19. Valve stem seal
20. Timing chain
21. Safety clip
22. Rocker arm
23. Valve spring
24. Valve-spring plate
25. Valve collets

1. 21.1. Remove timing chain housing.
   Fig 9: Removing Timing Chain Housing

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   1. Cheese head bolt → Tightening torque: 8 Nm (6 ft lbs.) 
   2. Timing chain housing
2. 21.2. Remove intake camshaft. Loosen the hexagon nuts on the bearing covers alternately and crosswise. Note the sequence in which the bearing covers are removed.
3. 21.2.1. Remove bearing covers 1 and 13.
4. 21.2.2. Remove bearing covers 3 and 11.
5. 21.2.3. Remove bearing cover 7.
6. 21.2.4. Remove bearing covers 5 and 9.
7. 21.3. Remove outlet camshaft. Loosen the hexagon nuts on the bearing covers alternately and crosswise. Note the sequence in which the bearing covers are removed.
8. 21.3.1. Remove bearing covers 2 and 14.
9. 21.3.2. Remove bearing covers 4 and 12.
10. 21.3.3. Remove bearing cover 8.
11. 21.3.4. Remove bearing covers 6 and 10.

1. 23.1. Remove and dispose of cylinder head gasket.

Information 

Removal of connecting-rod bearing cap: 

• Connecting-rod bearing caps must be marked and numbered during removal. Retaining lugs of bearing shells are pressed together. The cast lugs of connecting-rod bearings and connecting-rod big end are identical! 

Fig 11: Exploded View Of Crankshaft Joint Flange

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1. Cylinder block
2. Vibration balancer joint flange
3. Hexagon-head bolt on vibration balancer joint flange
4. Straight pin
5. Lower timing-case cover
6. Fastening screw on lower timing-case cover

1. 27.1. Unscrew hexagon-head bolts -3-  .
2. 27.2. Carefully lever off the joint flange -2-  with a screwdriver.

Information 

Removal of crankshaft 

Before removing the crankshaft, have a suitable tray ready so that the pulse-generating wheel is not damaged as a result of excessive contact.

The engine is secured on the engine support to facilitate assembly work.

When replacing bearing shells, only use bearing shells with the same colour coding.

Fig 12: Exploded View Of Crank Drive On V6 DFI Engine

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1. Crankshaft bearing covers
2. Internal serration screws on crankshaft bearing covers
3. Crankshaft bearing shells must always be replaced 
4. Thrust washer for bearing cover 5 must always be replaced 
5. Crankshaft
6. Drive plate for inductive pickup (speed sender)
7. Fastening screw on drive plate for inductive pickup (speed sender)
8. Oil spray jet

1. 28.1. Prepare a clean surface for laying down the crankshaft. Make sure not to damage the drive plate for the inductive pickup (speed sender) when laying down the crankshaft.
2. 28.2. Remove crankshaft bearing covers -1-  and lay them down arranged according to cylinder.
3. 28.3. Dispose of thrust washers -4-  and crankshaft bearing shells -3-  .
4. 28.4. Remove the crankshaft and lay it down on the prepared surface.
5. 28.5. Remove oil spray jets -8-  if necessary.