PRE-RELEASE
Crankshaft and pistons, to remove
| Crankshaft and pistons, to remove |
| To remove |
| 1. |
Remove the power unit, see
Power train removal
.
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| 2. |
Fit
32 025 020 Lifting eye
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| 3. |
Remove the torque arm from the subframe and the electrical connections from the EHPS unit.
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| 4. |
Lift off the power unit from the subframe using
83 92 409 Lifting yoke
.
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| 5. |
Remove the electrical connection from the starter motor and generator. Remove the wiring harness from the engine.
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| 6. |
Remove the starter motor.
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| 7. |
Remove the front catalytic converter bracket.
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| 8. |
Aut
: Undo the 6 bolts holding the torque converter to the driver plate. Rotate the engine clockwise with the pulley centre bolt.
Remove the gearbox oil cooling hoses and plug the holes and hoses with 82 92 955 Plugs, spare part kit . |
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| 9. |
Man
: Remove the gearbox bolts and lift it away from the engine.
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| 10. |
Aut
: Remove the gearbox bolts. Pull out the gearbox about 10 mm.
Undo the plug and press the torque converter against the gearbox, fit 87 92 574 Holder for holding the torque converter in place and remove the gearbox. |
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| 11. |
Remove the pipe to the coolant reservoir.
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| 12. |
Remove the coolant pipe leading to the oil cooler.
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| 13. |
Remove the EGR cooler assembly.
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| 14. |
Fit
32 025 017 Holder engine in stand
and
83 96 376 Adapter kit sockets x4
. Mount the engine on
78 74 878 Floor stand
.
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| 15. |
Drain the engine oil and remove the oil filter cap and the filter.
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| 16. |
Remove the intake manifold from the turbocharger.
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| 17. |
Remove the dipstick tube.
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| 18. |
Remove the heat shield.
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| 19. |
Remove the turbocharger oil delivery line and return line from the engine block.
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| 20. |
Remove the turbocharger with catalytic converter.
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| 21. |
Remove the AC bracket.
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| 22. |
Remove the generator.
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| 23. |
Remove the belt tensioner.
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| 24. |
Remove the vacuum container.
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| 25. |
Remove the crankcase ventilation hoses from the engine, oil sump and oil filler pipe.
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| 26. |
Remove the oil trap hose with quick coupling.
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| 27. |
Detach the wiring harness from the bracket.
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| 28. |
Remove the combustion circulation connector (403).
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| 29. |
Undo the vacuum pipe.
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| 30. |
Open the clip for the wiring harness.
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| 31. |
Remove the oil trap bracket.
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| 32. |
Remove the engine wiring harness by unplugging the following connectors:
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| 32.a. |
Pressure monitor, engine oil (44)
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| 32.b. |
Level sensor, engine oil (243)
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| 32.c. |
Crankshaft position sensor (345)
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| 32.d. |
EGR solenoid valve (606)
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| 32.e. |
Fuel quantity control valve, high-pressure pump (652b)
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| 32.f. |
Connector H11-1
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| 32.g. |
Camshaft position sensor (555).
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| 32.h. |
Injectors (206).
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| 32.i. |
Fuel pressure sensor (653).
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| 32.j. |
Fuel pressure control valve (652a).
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| 32.k. |
Throttle body actuator unit (604).
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| 32.l. |
Intake air sensor (688).
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| 32.m. |
Glow plug connector.
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| 32.n. |
Coolant temperature sensor (202).
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| 33. |
Remove the wiring harness clip (front).
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| 34. |
Lift off the wiring harness.
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| 35. |
Remove the vacuum pipe.
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| 36. |
Remove Actuator, combustion circulation (403).
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| 37. |
Remove the oil cooler complete with oil filter housing.
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| 38. |
Remove the idler wheel centre bolt on the lower timing cover. Use e.g. 2 screwdrivers to carefully prise from two directions.
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| 39. |
Remove the crankshaft pulley.
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| 40. |
Remove the upper timing cover.
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| 41. |
Remove the lower timing cover.
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| 42. |
Undo the crankcase ventilation pipe and hose form the camshaft housing.
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| 43. |
Zero the engine by removing the plug and fitting
32 025 008 Camshaft fixing tool
.
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| 44. |
Turn round the engine until the tool engages and locks the exhaust camshaft.
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| 45. |
Relieve the belt tensioner and remove the timing belt.
Mark the direction of rotation if the timing belt is not being changed. |
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| 46. |
Remove the fuel return hose from the fuel return collector.
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| 47. |
Remove the fuel delivery pipe between the pump and the fuel rail.
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| 48. |
Remove the fuel return hoses.
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| 49. |
Remove the fuel pipes from the injectors and fuel rail. Grip the injector with a spanner when undoing the pipe. Mark the pipes for easier assembly.
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| 50. |
Remove the injector with holder. If the nozzles cannot be lifted by hand, use
32 025 013 Removal tool, injectors
with
83 90 270 Sliding hammer
and
32 025 012 Adapter, sliding hammer
. Remove the injectors in the following order: 1-2-3-4.
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| 51. |
Remove the fuel rail and hose.
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| 52. |
Remove the bolt between the fuel pump bracket and cylinder head, screw out the spacer bolt a few turns.
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| 53. |
Remove the bracket to the turbocharger intake manifold.
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| 54. |
Undo and remove the camshaft housing and guide sleeves. Loosen bolts alternately as illustrated.
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| 55. |
Remove the cylinder head by undoing the bolts in the illustrated order.
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| 56. |
Carefully lift off the cylinder head.
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| 57. |
Remove the engine block guide sleeves.
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| 58. |
Remove the bracket to the fuel pump.
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| 59. |
Remove the crankshaft position sensor.
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| 60. |
Fit
83 92 987 Flywheel locking attachment
in the threaded hole in the oil sump so that the flywheel/driver plate is locked.
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| 61. |
Man
: Remove the bolts holding the pressure plate and remove the clutch.
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| 62. |
Man
: Remove the clutch plate.
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| 63. |
Remove the flywheel/driver plate.
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| 64. |
Remove the flywheel locking attachment.
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| 65. |
Change seal and fit the drain plug into the oil sump.
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| 66. |
Remove the oil sump bolts. Use
32 025 015 Extension piece Ribe M7
and
32 025 016 Extension piece Ribe M8
.
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| 67. |
Carefully prise loose the oil sump.
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| 68. |
Remove the oil intake pipe.
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| 69. |
Remove the rear crankshaft seal.
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| 70. |
Remove the belt pulley using
32 025 006 Holder, crankshaft
(a) in combination with
83 95 360 Holding tool, crankshaft pulley
(b).
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| 71. |
Remove the oil pump.
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| 72. |
Make a note of the marking on the connecting rods and bearing caps so they can be refitted in their original positions. Remove the connecting rod bearing caps. Remove the pistons and connecting rods from the cylinder bores of cylinders 2 and 3.
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| 73. |
Rotate the crankshaft a 1/2 turn. Note the markings on the connecting rods and bearing caps so they can be refitted in their original positions. Remove the connecting rod bearing caps. Remove the pistons and connecting rods from the cylinder bores in cylinders 1 and 4.
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| 74. |
Remove the bearing shell from the connecting rod and bearing cap. Do not get the bearing shells mixed up.
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| 75. |
Check the crankshaft end float using
78 40 622 Dial indicator
and
87 90 727 Bracket, dial gauge
.
If the bearing play is outside the above specifications, suitable thrust bearings must be used. |
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| 76. |
Remove the crankshaft bearing caps with lower bearing shells. Do not get the bearing shells mixed up.
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| 77. |
Lift out the crankshaft and the upper bearing shells. Do not get the bearing shells mixed up.
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| 78. |
Lift out the thrust bearings.
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| 79. |
Remove the piston cooling nozzles.
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