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To dismantle, engine block

To dismantle, engine block

To remove


1. Remove the power unit from the car. See To remove, power unit

2. Remove other equipment from the engine. See Engine on subframe, To remove - To fit

3. Remove the flywheel.


4. Remove the upper intake manifold.


5. Remove the turbo bracket and the turbo's water pipe.


6. Remove the bolts of the turbo's oil pipe from the cylinder block plus the EGR pipe.

7. Remove the heat shields and exhaust pipe bolts from the exhaust manifolds and the two large retaining screws from under the turbo.


8. Remove the turbocharger with pipe as a unit.

9. Fit 83 94 751 Holder, engine onto the engine and mount it in Floor stand 78 74 878 .

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.


11. Remove the oil filter.

12. Remove the dipstick.

13. Remove the heat shield from the exhaust manifolds.

14. Remove the rear and front exhaust manifolds.


15. Remove the starter motor.

16. Remove the water and oil pipes of the thermostat and oil filter housing from the connections on the cylinder block.


17. Remove the thermostat and oil filter housings.

18. Remove the timing belt cover.


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.


20. Remove the bolt of the crankshaft pulley. Check that the belt pulley has not become twisted. Remove the belt pulley.

21. Release the tension on the timing belt tension pulley by turning it slowly and carefully and inserting a 6 mm drill or the like in the hole. Remove the tension pulley by loosening the bolt and pull the tension pulley out simultaneously.


22. Remove the idler pulley, belt tensioner and belt pulley for the auxiliary equipment belt circuit.


23. Remove the idler pulleys for the timing belt. Use EN-47646 Holding tool, fuel pump



24. Remove the outer timing cover.

25. Turn the engine on the stand and remove the sheet metal oil sump.


26. Remove the upper oil sump.


27. Turn back the engine on the stand so that the remaining oil runs out.


28. Remove the engine harness connector and the engine harness with cable ducts.

29. Remove all fuel feed pipes with holders.


30. Detach the connector and remove the fuel rail.


31. Remove the EGR valve with cooling jacket.


32. Remove the coolant pipe and the fuel rail from the cylinder head.


33. Remove EGR and coolant pipe as one unit.


34. Remove the camshaft covers.


35. Remove the power steering pump with bracket as well as the lifting eyes.


36. Remove the injector bracket.


37. Remove the injectors with pipes as one unit from each cylinder bank.

38. Remove the studs of the injector bracket.


39. Remove the camshaft frames.

40. Remove the cylinder heads.


41. Remove the fuel feed pipes from the fuel pump.


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.

43. Fit two M6 bolts in the holes of the inner portion of the fuel pump gear and remove it.

44. Remove the fuel pump.

Important

The fuel pump must not be fitted at angle exceeding 45°.


45. Remove the crankshaft position sensor's sprocket and the inner timing cover.


46. Remove the timing belt.

47. Remove the coolant pump and the oil pump.


48. Turn the engine so that the underbody becomes accessible. Remove the main bearing member.


49. Remove all big-end bearing caps. Remove the pistons with connecting rods.


50. Remove the crankshaft seal housing.


51. Remove the rear crankshaft seal using 83 95 733 Removal tool, rear crankshaft seal .

52. Remove the main bearing caps by pulling them upwards using long bolts fastened in the threaded holes.


53. Remove the crankshaft.

54. Remove the piston cooling nozzles.


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.