To dismantle, engine block
To dismantle, engine block |
To remove |
1. |
Remove the power unit from the car. See
To remove, power unit
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2. |
Remove other equipment from the engine. See
Engine on subframe, To remove - To fit
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3. |
Remove the flywheel.
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4. |
Remove the upper intake manifold.
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5. |
Remove the turbo bracket and the turbo's water pipe.
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6. |
Remove the bolts of the turbo's oil pipe from the cylinder block plus the EGR pipe.
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7. |
Remove the heat shields and exhaust pipe bolts from the exhaust manifolds and the two large retaining screws from under the turbo.
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8. |
Remove the turbocharger with pipe as a unit.
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9. |
Fit
83 94 751 Holder, engine
onto the engine and mount it in
Floor stand 78 74 878
.
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10. |
Drain the oil from the oil sump via the drain plug and from the oil filter container via the plug in the filter container.
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11. |
Remove the oil filter.
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12. |
Remove the dipstick.
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13. |
Remove the heat shield from the exhaust manifolds.
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14. |
Remove the rear and front exhaust manifolds.
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15. |
Remove the starter motor.
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16. |
Remove the water and oil pipes of the thermostat and oil filter housing from the connections on the cylinder block.
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17. |
Remove the thermostat and oil filter housings.
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18. |
Remove the timing belt cover.
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19. |
Reset the engine by turning the crankshaft belt pulley so that the setting marks on the belt pulley and cam gear end up against the markings on the engine.
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20. |
Remove the bolt of the crankshaft pulley. Check that the belt pulley has not become twisted. Remove the belt pulley.
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22. |
Remove the idler pulley, belt tensioner and belt pulley for the auxiliary equipment belt circuit.
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23. |
Remove the idler pulleys for the timing belt. Use
EN-47646 Holding tool, fuel pump
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24. |
Remove the outer timing cover.
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25. |
Turn the engine on the stand and remove the sheet metal oil sump.
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26. |
Remove the upper oil sump.
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27. |
Turn back the engine on the stand so that the remaining oil runs out.
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28. |
Remove the engine harness connector and the engine harness with cable ducts.
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29. |
Remove all fuel feed pipes with holders.
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30. |
Detach the connector and remove the fuel rail.
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31. |
Remove the EGR valve with cooling jacket.
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32. |
Remove the coolant pipe and the fuel rail from the cylinder head.
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33. |
Remove EGR and coolant pipe as one unit.
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34. |
Remove the camshaft covers.
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35. |
Remove the power steering pump with bracket as well as the lifting eyes.
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36. |
Remove the injector bracket.
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37. |
Remove the injectors with pipes as one unit from each cylinder bank.
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38. |
Remove the studs of the injector bracket.
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39. |
Remove the camshaft frames.
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40. |
Remove the cylinder heads.
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41. |
Remove the fuel feed pipes from the fuel pump.
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42. |
Fit two M6 bolts in the holes of the fuel pump gear. Tighten the bolts alternately until the outer portion of the gear has loosened.
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43. |
Fit two M6 bolts in the holes of the inner portion of the fuel pump gear and remove it.
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44. |
Remove the fuel pump.
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45. |
Remove the crankshaft position sensor's sprocket and the inner timing cover.
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46. |
Remove the timing belt.
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47. |
Remove the coolant pump and the oil pump.
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48. |
Turn the engine so that the underbody becomes accessible. Remove the main bearing member.
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49. |
Remove all big-end bearing caps. Remove the pistons with connecting rods.
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50. |
Remove the crankshaft seal housing.
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51. |
Remove the rear crankshaft seal using
83 95 733 Removal tool, rear crankshaft seal
.
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52. |
Remove the main bearing caps by pulling them upwards using long bolts fastened in the threaded holes.
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53. |
Remove the crankshaft.
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54. |
Remove the piston cooling nozzles.
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55. |
Clean the parts and remove the remains of old gaskets. Check for wear on bearings, piston rings, etc. before fitting. Replace worn and faulty components.
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