Disassembling engine

→ Wear personal protective gear.

→ Get someone to help if necessary.

→ Secure components to prevent them from falling down.

→ 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, 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 brackets for engine mounts.
2. Remove drive belt and deflection rollers. → 137819 REMOVING AND INSTALLING DRIVE BELT
3. Remove air-conditioning compressor. → 873419 REMOVING AND REINSTALLING AIR-CONDITIONING COMPRESSOR
4. Remove exhaust manifold with turbocharger. → 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD
   1. 4.1. Remove turbocharger oil lines.
   2. 4.2. Remove turbocharger coolant lines.
5. Remove generator. → 272219 REMOVING AND INSTALLING GENERATOR
6. Remove ignition coils. → WM 282020 REMOVING AND INSTALLING IGNITION COILS
7. Remove spark plugs. → 287020 REMOVING AND INSTALLING SPARK PLUGS
8. Remove positive crankcase ventilation. → 105119 REMOVING AND INSTALLING POSITIVE CRANKCASE VENTILATION VALVE 
9. Remove high-pressure pump. → 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP
10. Remove fuel lines. → 249019 REMOVING AND INSTALLING FUEL LINE (HIGH-PRESSURE)
11. Remove the intake-air distributor. → 244619 REMOVING AND INSTALLING THE INTAKE-AIR DISTRIBUTOR
12. Remove fuel injectors with fuel collection pipe. → 244019 REMOVING AND INSTALLING FUEL INJECTOR
13. Remove engine wire harness. → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE
14. Remove secondary-air lines.
15. Remove the secondary-air pump. → 266519 REMOVING AND INSTALLING THE SECONDARY-AIR PUMP
16. Remove vacuum reservoir. → 245419 REMOVING AND INSTALLING VACUUM RESERVOIR
17. Remove front coolant lines for engine.
18. Remove coolant pump housing and coolant pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
19. Remove thermostat housing. → 195519 REMOVING AND INSTALLING HOUSING FOR COOLANT REGULATOR
20. Remove pulley. → 137619 REMOVING AND REINSTALLING PULLEY (VIBRATION BALANCER)
21. Remove belt tensioner. → 137319 REMOVING AND INSTALLING BELT TENSIONER
22. Remove cylinder head cover. → 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER
23. Remove pulse sender. → 287319 REMOVING AND INSTALLING CRANKSHAFT PULSE SENDER
24. Remove oil pan. → 175019 REMOVING AND INSTALLING OIL PAN
25. Remove oil cooler. → 174019 REMOVING AND INSTALLING OIL/WATER HEAT EXCHANGER
26. Remove oil pipes and oil plate.
27. Remove oil pump drive for oil pump and accessories. → 172019 REMOVING AND INSTALLING OIL PUMP
28. Remove oil pressure regulator (oil pan). → 175019 REMOVING AND INSTALLING OIL PAN
29. Remove oil pressure sensor. → 170419 REMOVING AND INSTALLING OIL-PRESSURE SENDER
30. Remove oil guide housing. → 175019 REMOVING AND REINSTALLING OIL GUIDE HOUSING
31. Remove the timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE COVER
32. Remove timing chain. → 153519 REMOVING AND INSTALLING TIMING CHAIN
33. Remove camshaft controllers. → 158419 REMOVING AND INSTALLING ACTUATOR FOR CAMSHAFT (CAMSHAFT CONTROLLER)
34. Remove camshafts. → 150520 REMOVING AND REINSTALLING CAMSHAFTS
35. Remove cylinder head. → 157019 REMOVING AND INSTALLING CYLINDER HEAD
36. Remove knock sensor. → 287219 REMOVING AND INSTALLING KNOCK SENSOR
37. Remove starter. → 276019 REMOVING AND INSTALLING STARTER
38. Remove lower part of crankcase.
39. Remove connecting rod with piston. → 131020 REMOVING AND INSTALLING PISTONS
40. Remove bearing shells and crankshaft.