Dismantling the engine block
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Dismantling the engine block
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Place the dismounted unit on the lifting trolley.
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1.
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Drain the engine oil and remove the starter motor.
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2.
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Dismantle the belt tensioner, remove the generator and support bearing bracket with pipe and the inboard drive shaft joint.
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3.
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Fit the holder, part no. 83 94 827, on the engine and lift the powertrain over to
78 74 878 Floor stand
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4.
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Remove the protective plate and undo the torque converter retaining bolts (aut.). Gradually withdraw the torque converter while rotating the crankshaft pulley.
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5.
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Secure the torque converter with a 50 mm long M6 bolt threaded up to its neck (aut.).
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6.
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Remove the gearbox.
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7.
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Unplug the ignition discharge module connector (turbo), remove the oil filler pipe mounting and detach the preheating hoses on the throttle body.
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8.
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Remove the bracket for the electrical connections.
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9.
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Loosen the positive crankcase ventilation nipple and remove the intake manifold stay.
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10.
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Unscrew the intake manifold retaining bolts and lift off the manifold from the engine.
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11.
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Remove the engine mounting bracket.
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12.
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Remove the filler pipe from the expansion tank.
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13.
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Remove the pipe to the heat exchanger.
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14.
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Remove the water pump and the sleeve with O-rings.
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15.
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Unfasten the crankcase ventilation pipe together with the intake manifold (turbo).
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16.
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Remove the turbocharger stay, detach the water and oil pipes (turbo) and remove the turbocharger.
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17.
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Remove the power steering pump and bracket.
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18.
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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.
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19.
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Remove the oil filter and the adapter housing.
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20.
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Remove the crankshaft position sensor.
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21.
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Remove the thermostat housing cover.
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22.
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Align the 0-marking on the flywheel or, alternatively, the companion disc with the marking on the end plate.
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24.
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Remove the flywheel locking segment and take off the flywheel or, alternatively, the companion disc.
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25.
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Remove the ignition discharge module (turbo) or, alternatively, the cover and detach the ignition cables (B204i).
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26.
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Remove the spark plugs and remove the camshaft cover.
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27.
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Remove the chain tensioner. First remove the plug, then use a 27 mm socket.
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28.
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Remove the camshaft sprockets and place the chain so that the cylinder head can be removed without problem.
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30.
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Turn the engine to a suitable working position and remove the oil sump.
Leave the guide sleeve in the cylinder block.
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31.
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Remove the oil pump and timing cover.
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32.
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Remove the top chain guide and chain tensioner for the balancer shaft chain.
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33.
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Remove the idler sprocket and balancer shaft chain.
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34.
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Remove the oil pump driver and sprocket from the crankshaft.
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35.
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Remove the balancer shaft and timing chain guides.
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36.
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Remove the timing chain guard and remove the chain complete with sprocket.
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37.
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Remove the balancer shafts complete with sprockets and bearing housings.
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Important
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Turn the balancer shafts 180˚ so that the weights are pointing upwards and remove them carefully so the bearing bushings are not damaged.
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38.
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Remove the end plate.
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39.
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Remove any carbon deposits from the edges, turn the engine into a convenient position and remove all big-end bearing caps.
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Important
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When dismantling bearing caps and shells, store them carefully and in the right order so that they can be reassembled in their original positions.
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41.
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Remove all main bearing caps and lift out the crankshaft.
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42.
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Remove the slotted ring.
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Important
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Observe the utmost care when handling the slotted ring.
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43.
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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.
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44.
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Remove the piston cooling nozzles.
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