Part 1

Disassembling and assembling engine

















Preliminary Work

1. Remove engine
2. Remove transmission.
3. Secure the engine support to the engine/transmission flange with screw sleeves.
4. Secure the engine to the assembly support with an engine lift. Get another person to help you do this.

Additional steps required for complete disassembly before fitting the engine support:

5. Remove the clutch.
6. Remove flywheel or drive plate for converter.





Adapter for engine support

If complete disassembly is not required, the flywheel and clutch can remain fitted. In this case, the adapter for engine support 9667 must be fitted.

Disassembling engine down to cylinder housing

Disassembling engine

Caution
Risk of damage due to particles of dirt.
^ Danger of material damage due to blocked oil bores/oil ducts.

- Absolute cleanliness is essential when working on the engine.

- Lay removed engine parts on a clean base and make sure to cover them.

- Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

1. Place a pan under the engine to collect emerging fluids.
2. Drain engine oil. Also loosen the oil filter at the bracket so that the remaining oil can drain more easily.
3. Remove rear silencer.
3.1. Screw off four M8 lock nuts on the turbochargers.
3.2. Open the holding clamps on the engine carrier and get another person to help you to remove the silencer.
4. Remove intake air pipes.
4.1. Unclip vacuum lines for the ambient air valves on the turbocharger.
4.2. Unscrew two Torx screws (M6) -arrows- on the turbochargers. Disengage intake pipes from the holders and remove them.





Intake air pipe, connector on electronic adjuster for turbocharger (view of side 4-6)

5. Remove oil and coolant supply lines on the turbocharger.
6. Remove turbocharger on side 1-3. Loosen threaded connection on holder for turbocharger 1-3 and take off turbocharger.
7. Remove turbocharger on side 4-6. Loosen threaded connection on holder for turbocharger 4-6 and take off turbocharger.
8. Remove secondary-air pump.
8.1. Unclip vent line for the oil tank.
8.2. Unscrew two M6 Torx screws and disconnect cable plug.
9. Remove engine carrier by unscrewing four Torx screws (M10 x 70) and remove bracket.
10. Remove the oil extraction lines for the oil tank at the turbocharger.
10.1. Unscrew two M6 x 12 Torx screws and pull off lines.
11. Remove oil return line for engine extraction pump.
11.1. Unscrew M16 banjo bolt and remove (replace) two aluminium sealing rings.
12. Remove oil tank.
12.1. Unscrew three M8 x 30 Torx screws.
12.2. Loosen five clamps for the breather hoses and pull off the hoses.
12.3. Loosen the union nut (a/f 32) on the oil line and put it aside. Disconnect cable plug for oil-level sender.
12.4. Unscrew two Torx screws (M6 x 16) on the feed line from the engine and remove (replace) O-ring.
13. Remove heat shields for ignition coils. Loosen and unscrew two Torx screws (M6 x 12) on each and remove heat shields.
14. Loosen ground cable on cover for camshaft housing 1-3 and 4-6. Unscrew one Torx screw (M6 x 35) on each.
15. Disconnect all plug connections for the engine wire harness in order to remove the intake manifold.
15.1. Slide engine compartment temperature sensor out of the rubber sleeve.
15.2. Unclip cable duct on intake distributor 4-6 (three clip points).
16. Disengage vent line for oil/water heat exchanger.





View of intake distributor side 1-3

17. Remove intake manifold.
17.1. Unscrew six hexagon socket head bolts (M6 x 25) on each, together with the captive washer -1-. Tool recommendation: Long socket head insert with ball joint.





Intake distributor screw connection

17.2. Loosen the throttle body holder at the oil-filter console by unscrewing one M6 hexagon nut.





Fuel connection to pressure regulator

17.3. Loosen fuel line on pressure regulator for fuel collection pipe on side 4-6. Screw on M14 union nut (a/f 19) -1- and counter at the pressure regulator at the same time with an open-ended wrench (a/f 22).
17.4. Loosen the line for the turbocharger switch-over valve at the distributor pipe by opening the screw-type clamp and pulling off the line.
17.5. Pull off vacuum line on the connection to the tandem pump. Remove switch-over valve and lines.
17.6. Lift up the intake manifold and disconnect the secondary air line at the shut-off valve, side 4-6.
17.7. Completely remove the intake manifold.
18. Remove combination valves for secondary air for cylinders 1-3 and 4-6.
18.1. Disconnect secondary air line on combination valve for side 1-3 -2- and 4-6. Remove all lines.
18.2. Unscrew three hexagon socket head bolts (M6 x 20) on each, together with the captive washer -1-. Remove valves and dispose of O-rings.





Combination valve for secondary air

19. Remove vent lines -1- on the oil/water heat exchangers. Open two screw-type clamps and pull off the hoses.





Vent lines on oil/water heat exchangers

20. Loosen hydraulic line for the clutch at the power-steering supply tank by pressing the plastic sleeve towards the tank using the disassembly tool Nr.21 and pull out the line.





Diagrammatic view of removing hydraulic line

21. Unclip vent line for turbocharger 1-3 and remove line.
22. Remove coolant run-on pump.
22.1. Pull off cable plugs -1 and 2-.





Cable plugs for coolant run-on pump

22.2. Open the clamp -1- and remove lines for the turbochargers.





Coolant line for run-on pump

22.3. Unscrew M6 x 12 fastening screw -2-, open the screw-type clamp -1- and pull off the coolant hose. Remove run-on pump -3-.





Run-on pump

23. Remove generator.
24. Remove the oil return line from the engine to the oil/water heat exchanger.
24.1. Unscrew two M6 x 16 Torx screws -11- on the heat exchanger and remove the metal seal.





Oil return line from engine to oil/water heat exchanger

24.2. Loosen the union nut (a/f 32) on the lower side of the crankcase and remove the line -2-.





Mounting for plastic holder for heater pipes

25. Unscrew two M6 x 55 Torx screws for the heater pipe holder -1- and B+ line.
25.1. Slide the plastic holder to the left to remove it -arrow-.





Holder for heater pipes

26. Unclip power-steering lines for the power-assisted clutch and loosen and remove lines at the tank.
27. Loosen fuel lines -1- at the fuel cooler - make sure to counter with an open-ended wrench (a/f 17/15 -2-) while doing this.





Fuel lines at the fuel cooler

28. Remove air conditioning compressor.





Cable plug for air conditioning compressor

28.1. Disconnect plug connection for air conditioning compressor -1-.
29. Disconnect other cable plug connections.
29.1. Knock sensors.





Combination connector for oil pressure/oil temperature

29.2. Combination connector -1-for oil pressure and oil temperature.
29.3. Terminal 50 from generator.
30. Release cable duct -2-. Unscrew two Torx screws (M6 x 16) -1- (on cylinder side 1-3 with fuel line attachment).





Cable duct attachment

31. Remove wire harness with temperature sensor for turbocharger. Unclip lines for exhaust temperature sensors at two places.
32. Take off fuel line on side 1-3.
33. Remove the two holders for the turbochargers.





Turbocharger holder, side 1-3

33.1. Side 1-3: unscrew two Torx screws -11- (M8 x 20 and M8 x 35) and remove holder -2- and ground cable.





Turbocharger holder, side 4-6

33.2. Side 4-6: unscrew two Torx screws -11- (M8 x 20 and M8 x 35) and remove holder -2-.
34. Remove oil return line for the oil tank by loosening one union nut (a/f 27) on oil suction pump 1-3 and 46.
35. Remove oil supply lines for the turbochargers.





Oil supply line for turbocharger 1-3

35.1. Side 1-3: unscrew one M6 x 10 Torx socket screw (stainless steel) -2- and dispose of O-ring.





Oil supply line for turbocharger 4-6

35.2. Side 4-6: unscrew one M6 x 10 Torx socket screw (stainless steel) -1- and dispose of O-ring.
36. Remove coolant lines on cylinder side 1-3.





Screw-type clamps on coolant lines

36.1. Open one screw-type clamp on the heater pipe return line -2- and two screw-type clamps on the supply line for the water pump and thermostat -1-.
36.2. Loosen screw-type clamps -1- on the coolant lines at the heat exchanger bracket.





Coolant connection for heater and heat exchanger bracket





Coolant pipes

37. Remove coolant pipes -2-. Replace sealing sleeves -3- when joining the pipes again.





Coolant hose on left coolant pipe

37.1. Left coolant pipe: open the screw-type clamp and unscrew two Torx screws (M6 x 20). Remove coolant pipe.
37.2. Right coolant pipe: unscrew two Torx screws (M6 x 20) and remove coolant pipe.
38. Unscrew fastening screw (M6 x 16) for B+ line at transport eyelet and remove line.
39. Remove the two oil/water heat exchangers. A holder -2- is also secured to the small heat exchanger.
39.1. Unscrew four Torx screws (M6 x 16) -1- on the small heat exchanger.





Small oil/water heat exchanger





Large oil/water heat exchanger

39.2. Unscrew four Torx screws (M6 x 16) -1- on the large heat exchanger.
39.3. Replace O-rings during installation: four O-rings on the large heat exchanger -1- and three O-rings on the small heat exchanger -2-.





Allocation of O-rings to oil/water heat exchanger

40. Remove heat exchanger bracket.
40.1. Unscrew four coated Torx socket screws (M6 x 20) -1-.





Heat exchanger bracket threaded joint

41. Loosen holder for oil-filter console by removing two Torx screws (M6 x 16) -1-.





Holder for oil-filter console

42. Take off the heat exchanger bracket. Dispose of O-rings.
42.1. Slide the handle of a wooden hammer under the bracket and carefully lever the bracket off.
42.2. Place a clean absorbent cloth underneath to catch residual fluid.
43. Remove secondary unit carrier. Unscrew four Torx screws (M10 x 60) -1-. Remove unit carrier and power steering pump.





Removing secondary unit carrier

44. Take off coolant guide housing together with water pump and oil suction pump. Collect emerging coolant.
45. Remove exhaust manifold. Unscrew nine M8 x 28 screws -1- on each. Remove exhaust manifold -2- with metal seal.





Exhaust manifold threaded joint

46. Remove six ignition coils. Unscrew two Torx socket screws (M6 x 25) on each and take off the coils.
47. Remove six spark plugs. Always make sure to use spark plug socket wrench Nr.14 and extension Nr.15 to avoid damaging the ceramic body.
48. Remove oil suction pump/tandem pump.
48.1. Tandem pump, side 1-3: unscrew three Torx screws (M6 x 35), remove cable holder on exhaust temperature sensor and take off pump.
48.2. Suction pump, side 4-6: unscrew three Torx screws (M6 x 35) and takeoff pump.
49. Remove camshaft actuator lid. Remove three Torx screws (M6 x 20) and one cable holder for oxygen sensors.
50. Remove solenoid hydraulic valves for camshaft adjustment. Unscrew two M6 x 20 Torx screws (micro-self-locking) on each and pull out valves.
51. Remove pulse sender and holder.





Removing pulse sender

51.1. Unscrew two Torx screws (one M6 x 35, one M6 x 25) and remove pulse sender and cable.





Pulse sender plug connection holder

51.2. Unscrew M6 fastening screw -1- on the cylinder head and remove holder -2-.

Information
Do not remove the screw securing the chain in place (sealed screw).

52. Remove cover for camshaft housing.





Sealed screw securing timing chain in place

52.1. Do not remove sealed screw securing the timing chain -1- in place.





Camshaft housing cover

52.2. Unscrew 17 Torx screws -1- from the inside out (16 M6 x 35 screws and one M6 x 75 screw).
52.3. Remove all holders.





Lifting off camshaft housing cover

52.4. Carefully lever off the housing cover using a large screwdriver if necessary.

53. Remove camshafts.

Notice
Interchanged or dirty bucket tappets
^ Scoring on cylinder head

- Since the bucket tappets have been run in in the fitting bores, do not interchange them.

- Absolute cleanliness is essential.

Notice
Interchanged or dirty bucket tappets
^ Scoring on cylinder head

- Since the bucket tappets have been run in in the fitting bores, do not interchange them.

- Absolute cleanliness is essential.

54. Remove bucket tappets and switchable tappets. Check parts for signs of wear and replace if necessary.
54.1. Lay components down in such a way that they can be inserted again at their original position during reinstallation. Designate a clean surface, for example, for this purpose.
55. Remove camshaft housing.
55.1. Loosen 18 M8 x 50 Torx screws according to specifications and unscrew them. Remove housing and take out metal seal.
56. Be careful with the aluminium sleeve -1- on the timing chain box.





Aluminium sleeve on chain box

57. Remove cylinder head.
57.1. Remove 12 internal serration collar nuts (M12) using a socket wrench 9295.
57.2. Carefully lift off the cylinder head and remove the cylinder head gasket.
58. Replace guide and tensioning rails.





Bearing pins for guide rail

58.1. Guide rail: unscrew two bearing pins of different lengths. Top 69 mm (chain box) -2-, bottom = 74.5 mm (crankcase) -1- and dispose of sealing ring.
58.2. Lift the rail out of the chain box.
58.3. Tensioning rail: unscrew one threaded bolt with a length of 74.5 mm (crankcase) and dispose of sealing ring.
58.4. Lift the rail out of the chain box.





Pins for guide and tensioning rails

^ 1 - Pin = 69 mm
^ 2 - Pin = 74.5 mm

59. Remove chain box.
59.1. Remove five M8 screws: two M8 x 35 screws with washer (on the dowel sleeves), two M8 x 30 screws with washer, one M8 x 25 Torx screw.
59.2. Dispose of metal seal.
60. Remove coolant connection piece on cylinder housing. Unscrew two Torx screws (M6 x 20), takeoff connection piece and dispose of O-ring.
61. Carefully clean all components and sealing surfaces.

Remove cylinder side 4-6 in the same way as cylinder side 1-3.