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To dismantle the engine

To dismantle the engine


Place the dismounted engine on the trolley.


1. Drain the engine oil and remove the starter motor.

2. Dismantle the belt tensioner, remove the generator and support bearing bracket with pipe and the inboard drive shaft joint.

3. Fit the retainer, part no. 83 94 728, on the engine and lift over the engine to the floor stand, part no. 78 74 878.


4. Remove the protective plate and undo the torque converter retaining bolts (aut.). Gradually withdraw the torque converter while rotating the crankshaft pulley.

5. Secure the torque converter with a 50 mm long M6 bolt threaded up to its neck (aut.).

6. Remove the gearbox.


7. Unplug the ignition discharge module connector (turbo), remove the oil filler pipe mounting and detach the preheating hoses on the throttle body.


8. Remove the bracket for the electrical connections.

9. Loosen the positive crankcase ventilation nipple and remove the intake manifold stay.

10. Unscrew the intake manifold retaining bolts and lift off the manifold from the engine.

11. Remove the engine mounting bracket.


12. Remove the filler pipe from the expansion tank.

13. Remove the pipe to the heat exchanger.

14. Remove the water pump and the sleeve with O-rings.

15. Unfasten the crankcase ventilation pipe together with the intake manifold (turbo).

16. Remove the turbocharger stay, detach the water and oil pipes (turbo) and remove the turbocharger.

17. Remove the power steering pump and bracket.

18. Remove the exhaust manifold. On a two-part exhaust manifold, the inner part is removed first and then the outer part. Note that there are sleeves on the outer studs only.

19. Remove the oil filter and the adapter housing.

20. Remove the crankshaft position sensor.

21. Remove the thermostat housing cover.


22. Align the 0-marking on the flywheel or, alternatively, the companion disc with the marking on the end plate.


23. Fit the flywheel locking segment, part no. 83 94 868, and remove the crankshaft pulley.

24. Remove the fly wheel locking segment and take off the flywheel or, alternatively, the companion disc.

25. Remove the ignition discharge module (turbo) and detach the ignition leads (B204i/B234i).


26. Remove the spark plugs and remove the camshaft cover.

27. Remove the chain tensioner. First remove the plug, then use a 27 mm socket.


28. Remove the camshaft sprockets and place the chain so that the cylinder head can be removed without problem.

29. Remove the cylinder head. Start with the bolts in the timing cover and continue in reverse order to assembly. Use protective sleeve, part no. 75 19 531, to retrieve the bolts.


30. Turn the engine to a suitable working position and remove the oil sump.


Leave the guide sleeve in the cylinder block.

31. Remove the oil pump and timing cover.


32. Remove the top chain guide and chain tensioner for the balancer-shaft chain.


33. Remove the idler sprocket and balancer-shaft chain.

34. Remove the oil pump driver and sprocket from the crankshaft.

35. Remove the balancer shaft and camshaft chain guides.


36. Remove the timing chain guard and remove the chain complete with sprocket.

37. Remove the balancer shafts complete with sprockets and bearing housings.

Important

Turn the balancer shafts 180° so that the weights are pointing upwards and remove them carefully so the bearing bushings are not damaged.


38. Remove the end plate.


39. Remove any carbon deposits from the edges, turn the engine into a convenient position and remove all big-end bearing caps.


Important

When dismantling bearing caps and shells, store them carefully and in the right order so that they can be reassembled in their original positions.


40. Fit the protective sleeve, part no. 75 19 531, onto the studs and press or carefully tap the pistons out of the cylinders.

41. Remove all main bearing caps and lift out the crankshaft.

42. Remove the slotted ring.

Important

Observe the utmost care when handling the slotted ring.


43. Remove all the bearing shells for both the main bearings and big-end bearings. Also remove the two thrust washers from main bearing no. 3.

44. Remove the piston cooling nozzles.