9 Remove the port bracket for the upper cover. 2 Remove the return fuel line (1) between the injectors and the return fuel block by pressing in the locking clip and wiggling loose the nipple. Remove the retum fuel block (2). a Remove the delivery pipe between the high pressure Pump and the rail as well as the delivery pipes to the injectors. Use nozzle tool 885 490. Detach the injector connectors. AX IMPORTANT! Fit protective caps to all fuel connections. Use protective caps in kit 885 510. 1920 2 Remove the bolt and spacer sieeve for the injector caliper. Fit puller 885 515 and prise up the injector. ZX IMPORTANT! Apply the tool only to the location described above, never anywhere else. ZX IMPORTANT! Fit protective caps on the injector tip and electrical connection. Use protective caps in kit 885 510. 23 Detach the cannector to the rail pressure sensor. Remove the rail. a Remove the cable hamess in one piece. Detach the following connectors on the port side of the engine: = Charge air pressure/charge air temperature sensor(1) = Oilpressure switch/Oil pressure sensor (2) = Starter motor (3) (detach only the cables belong- ing to the engine cable harness) = Railpressure sensor (detached earlier) = Monitor for water in ue! fiter (detached earlier) — _ Railpressure sensor (detached earlier) = High pressure pump (4) Detach the cable harness from the cable irons (6) bolt- ed to the oll sump screws.2 ‘The following cable connections are detached from above: = Injectors (detachedeariier) Undo the clamps (1) holding the cable harness to the valve cover. Remove the cable harness to the injectors. 6 The following connections are detached from astern: = DC/DC converter (detachedeartier) — Flywheel timing sensor (1) (the sensor can be de- tached from the engine including the bracket (2), a Detach the following connectors on the starboard side of the engine: = Camshatt sensor (1) (the sensor can be detached fromthe engine) = Coolanttemperature sensor (detached earlier) = Alternator (detachedearler) = Coolantievelalarm (detachedeartier) Detach the cable hamess from the cable irons (2) bolt- ed to the oll sump screws. 2122 2B Undo the nuts and bolts holding the starboard bracket (1) to the upper cover and remove the complete cable harness. Refer to workshop manual "Electrical System EVC" {or troubleshooting and repairing the electrical system. 2 Remove the exhaust pipe elbow. Remove the turbocharger support bracket 30 Remove the turbocharger air iniet elbow. Discard the O-ring between the compressor housing and the air pipe elbowa Remove the turbocharger cil feed hose (1). Use oil pipe too! 885 500 for the nipple in the cylinder block. Remove the oil return pipe (2). ZX IMPORTANT! Plug the turbocharger oil connections. 32 Remove the turbocharger. 3 Remove the thermostat housing (1) with its thermo- stat. Carefully pry loose the housing with two screwdrivers. 23a Remove the exhaust pipe (1). Remove the sea water pump. 6 Remove the port engine mounting bracket.7 Remove the starter motor. Use a 14 mm socket and long extension bar. 8 Remove the heat exchangericil cooler. Remove the return fuel cooler bracket (1) and the intake manifold, NB! Do not forget to undo the bolt under the attaching lugs for the fue! filter bracket. Loosen the intake manifold by carefully pry between the timing chain tensioner and the intake manifold. 2526 0 Remove the fuel pump and its spacer flange as one unit. Remove the gear and spacer flange if necessary: refer to "High pressure pump, replace’. a Remove the circulation pump belt pulley. Use a suita- ble screwdriver as a counterhold. 2 Remove the circulation pump. Discard the gasket.a Fit lock pin 885 504 into the flywheel housing. Press in the lock pin while turning the crankshaft until the pin engages in the flywheel. Remove the crankshaft belt pulley (1) and the oscilla- tion damper (2). a Remove the crankcase ventilation cover if necessary (leakage or sever fouling). 45 Remove the cover over the timing chain sprockets. Carefully tap in a knife to break the gasket seal. Remove the two studs (1) trom the cover (to allow the. camshafts to be removed later). 2728 885 493 «6 Remove the plugs from the valve cover and fit lock pin 885 493 (2 off). Make sure the lock pins engage in the camshafts (rotate the crankshaft 360°). a Remove the chain tensioner. ZX IMPORTANT! The crankshaft and camshafts must not be rotated after removing the chain tensioner unt the valve cover has been re- moved. This is so that the valves will not collide with the pistons. 8 Remove the upper chain guide. NB! Be caruful not to drop the bots.49 Undo the bolts on the timing chain sprockets and remove the sprockets, NBI The bolts are le't-hand thread. Lock pins 885 493 act as a backstop. 50 Undo the bolt (1) with its sealing washer (2) and lft out the starboard chain guide (3). 51 Undo the bolts on the valve cover (camshaft housing). Place a lever as illustrated and carefully pry loose the valve cover. Remove the lock pins 885 493, iit off the valve cover and place it on the work bench with the camshafts up. 2930 82 Remove the camshaft thrust washer. 53, Put the valve cover on one end. Screw in drift 885 506 (left-hand thread) on the starboard camshaft and knock carefully with a plastic mallet until tne tooth wheel (1) comes loose. cy Remove the tooth wheel and carefull it up the cam- shaft using the drift. ‘Transfer the too! to the port camshaft and lft it up.5 Remove the valve caliper (1) together with the finger followers (2) and place them in a vessel containing clean engine oil. NB! The finger followers may only be washed in clean engine oil 36 Undo the cylinder head bolts with power socket 885 509. necessary. for example when working in confined engine compartments, use torque amplifier 885 633 together with counterhold 885 648. Place the counter- hold in the front or rear lifting eye depending on which boltis being loosened. Undo the bolts gradually, start with the front and rear. It torque amplifier is used the front iting eye must temporarily be removed when the front eylinder head bolts are loosened, Lift off the cylinder head. 7 ZX IMPORTANT! Remove the non-return valves in the cylinder head ol passages before washing, Refer also to the chapter "Cylinder head disassembly’. 3132 ‘Tum over the engine and undo the bolts in the oil ‘sump. Mark the location of the brackets for the cable harness to facilitate assembly. Hammer in a putty knife between the cylinder block and the oll sump to break the gasket seal. Realign the sump with a plastic mallet afterwards it necassary. The oil sump side plates are removed only it deemed necessary (leaks) Remove the bolts and carefully liftoff the oil pump, from its locating pins. oo ‘Mark up where the oil splash plate (1) is located Remove the balance shaft housing (2) D4 and the re- inforcing housing D6.a Remove the pipes for draining the crankcase ventila- tion and the oil extractor. Use an M8 bolt to knock them out with a plastic mallet. 2 Remove the flywheel. Use lock pin 885 504 as a ccounterhold. a Undo all the bolts (do not forget the M8 bolts in the re- cess for the high pressure pump) and remove the rear ling eye and flywheel housing, Tap carefully with a plastic mallet to break the adhesive seal. Lift off the timing chain. 3334 a Undo the bolts for the front crankshaft cover. Place a lever as illustrated and carefully pry loose the crankshaft cover. cy ‘Tum the crankshaft so that the piston cooling nozzle is visible and remove the nozzle. Repeat this process. on the remaining cylinders. NB! The piston cooling nozzles must be removed at this stage to enable the pistons to be removed. Undo the big-end bearing caps with an external TX E14 socket. Fit guide pin 885 501 and pressiknock out the piston ‘and connecting rod. Where necessary, scrape away the carbon from the top of the cylinder. QQ IMPORTANT! Handle the connecting rod and ;p with care. The split surfaces are very impact sensitive. Discard f damaged, NB! The connecting rod and cap should be washed soparately,or Undo the main bearing caps using power socket {885 509 and lft out tne crankshaft Undo the idler gear centre bolt (1) and lft off the idler gear (2) from the journal. e Remove the idler gear journal. 3536 7 Undo the bolts (1) in the side plate (2). Tap carefully with a plastic mallet to break the adhesive seal n Remove the plug (1) and pull out the spring and the piston cooling valve. Remove the oil pressure/temperature sensor (2). R Remove the plugs (1) and (2) from the cylinder block oll passages atthe front and rear ends. Wash all engine components. Take special care when flushing the oil passages in the cylinder block and cylinder head,Engine, assemble 1 Fit the plugs into the cylinder block oil passages at the front and rear ends. Apply sealant (brown) to the plugs, part number 1161 370. 2 Fit the idler gear journal. Tightening torque 25 Nm. 373a AX IMPORTANT! The next part to assemble is the side plate but to ensure a good seal between the cylinder block and the side plate, its extremely important that the fywheel housing be fited and torque tightened within 30 minutes of fiting the side plate. The following should theretore be prepared beforehand! a. Lay out the idler whee! with its washer and bolt, Oil the bearing bushing, b. Fitnew main bearings in the cylinder block and caps. Place the main bearing shells with oil grooves in the cylinder block. Place the main bearing shells with associated axial bearings (1) in the rear main bearing position and the associated cap (marked °5° (D4) and "7" (D6) respectively). Oil all the main bearing shells. 38