Part 1
WM 1001Z1 Disassembling engineTools
Technical values
Preliminary work
Preliminary work for engine MA.120
NOTICE
Dirt and contamination
- Risk of damage to units or components
-> Protect components from dirt and contamination.
-> Clean or replace dirty components.
Information
- All engine repairs must be carried out using only the specified tools.
- Only these tools have been tested and approved.
Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E.) for external Torx, (T.) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
1. Remove the engine.
-> 100119 Removing and installing engine 100119 Removing and installing engine.
2. Support the engine on the engine assembly support.
-> 1001IN Tools for removing units and working on the engine assembly support Tools and Equipment.
3. Drain engine oil.
3.1. Unscrew drain plug and collect emerging oil.
3.2. Then screw in drain plug with a new sealing ring and tighten to the specified torque.
=> Tightening torque: 50 Nm (37 ftlb.)
4. Remove engine carrier -1-.
4.1. Unscrew four hexagon-head bolts (a/f 16): one M10 x 35 -2- , one M10 x 65 -3- , one M10 x 115 -4- and one M10 x 135 -5-.
Engine carrier screws
4.2. Remove engine carrier.
5. Completely remove intake-air distributor.
-> 244619 Removing and installing intake-air distributor Service and Repair.
5.1. Pull out engine compartment temperature sensor -1- with rubber sleeve -2-.
Engine compartment temperature sensor with rubber sleeve
5.2. Pull cable clip out of the intake-air distributor for cylinder bank 1-3.
5.3. Pull fuel line and rubber sleeve out of the holder.
5.4. Pull off cable plugs:
- Control valves for tuning flaps (2x)
- Fuel injectors (6x) -1-
- Tank vent
- Throttle potentiometer (electronic throttle)
Cable plug for injection valves
5.5. Pull vacuum line off the distributor cross -1-.
T-piece on vacuum lines for intake-air distributor
5.6. Unscrew external Torx screw (E10, M6 x 12) on the air-conditioning line holder.
5.7. Unscrew twelve external Torx screws (E10, M6 x 35) on the intake-air distributor.
5.8. Unscrew two external Torx screws (E10, M6 x 12) on the cable ducts.
5.9. Unscrew hexagon nut (a/f 10) on the throttle housing holder.
5.10. Completely remove the intake-air distributor.
5.11. Cover intake ports on the cylinder head.
6. Overview of components on belt side (removal steps described below).
Overview of components on belt side
7. Loosen three external Torx screws (E10, M8 x 12) on the hydraulic pump pulley (do not unscrew fully).
8. Remove drive belt.
-> 137819 Removing and installing drive belt Service and Repair.
9. Remove pulley for hydraulic pump by unscrewing three M8 external Torx screws.
10. Expose oxygen sensor cable -1- (exhaust manifold was already removed when you removed the engine).
Oxygen sensor cable (view of cylinder bank 1-3)
11. Remove heat shields. The upper parts do not have to be unscrewed separately.
Screws on heat shield
11.1. Unscrew four external Torx screws (E10, M6 x 12) -1- on each one.
11.2. Remove heat shields.
Information
- Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire harness).
- -> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine.
12. Disconnect various connectors on the engine wire harness.
-> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine.
12.1. Pull off the following cable plugs:
- Camshaft adjustment (2x)
- Valve lift adjustment (2x) -3-
- Hall sender (2x) -4-
- Coolant temperature sensor
- Knock sensors (2x)
- Secondary-air pump
- Generator
- Air conditioning compressor
- Oil pressure control valve
- Ignition coils (6x) -1-
- Sensor for oil pressure and oil temperature
- Oil level sensor
Overview of cable plugs and cable routing on cylinder head cover
12.2. Unscrew two internal Torx screws (T40, M6 x 12) -2- on the ground cables for the bar ignition modules for each cylinder bank.
12.3. Unscrew one external Torx screw (E12, M8 x 16) -1- on each cable duct for cylinder bank 1-3 and 4-6.
Cable duct screws
12.4. Unclip cable duct on cylinder bank 1-3 and 4-6 towards the belt side.
13. Remove ignition coils.
-> 282020 Removing and installing ignition coils Service and Repair.
14. Remove spark plugs.
-> 287020 Removing and installing spark plugs Service and Repair.
15. Remove crankcase vent line -1-.
15.1. Press locking ring on cylinder head cover 1-3 and pull off the line.
15.2. Press locking ring and pull off line at the oil filler neck.
15.3. Press locking ring on vent cover for cylinder head 4-6 and pull off the line.
15.4. Unscrew one Torx screw (E10, M6 x 20) on the oil separator and pull off the line. Replace O-rings.
Crankcase vent line
16. Remove oil separator -1-.
16.1. Unscrew two external Torx screws (E10, M6 x 25) -2-.
16.2. Pull off oil separator.
16.3. Replace O-rings.
Oil separator
17. Remove generator.
-> 272219 Removing and installing generator Service and Repair.
17.1. Pull protection cap -1- off the generator.
Protection cap on generator B+ line
17.2. Disconnect B+ line. To do this, unscrew one M8 collar nut.
17.3. Unscrew two external Torx screws (E12, M8 x 90) and remove the generator.
18. Disconnect B+ wire harness.
18.1. Loosen B+ line at the junction point -1- and pull protection cap -2- off the starter.
Junction point for B+ line and protection cap on starter
18.2. Unscrew M6 hexagon nut (a/f 10) for terminal 50 on the solenoid switch for the starter.
18.3. Unscrew hexagon nut (a/f 13) on the B+ line for the starter.
18.4. Remove wire harness.
19. Remove air conditioning compressor.
-> 873419 Removing and installing air conditioning compressor Service and Repair.
20. Remove coolant connection piece on cylinder bank 4-6.
-> 195919 Removing and installing coolant connection piece 195919 Removing and installing coolant connection piece on cylinder bank 4-6.
20.1. Unscrew three external Torx screws (E12, M8 x 70).
20.2. Unscrew one external Torx screw (E10, M6 x 25).
20.3. Remove coolant connection piece.
21. Loosen holder for hydraulic lines on cylinder head 4-6.
22. Remove hydraulic pump for power steering.
-> 489819 Removing and installing hydraulic pump - as of model year 2009 Service and Repair.
23. Use turning device 9773 -1- to turn the engine clockwise at the vibration damper until the TDC 1/4 marking on the vibration damper is aligned with the bore in the crankcase.
TDC marking on cylinder 1/4 on vibration damper
23.1. Secure the engine using one of the locating pins 9595/1 -2- on the vibration damper.
24. Remove vibration damper.
-> 137519 Removing and installing vibration damper Service and Repair.
25. Remove coolant regulator cover.
-> 195519 Removing and installing coolant regulator cover 195519 Removing and installing coolant regulator cover.
25.1. Unscrew three external Torx screws (E10, M6 x 50) and remove cover and coolant regulator.
25.2. Replace O-ring.
26. Remove coolant guide -1- at the bottom.
26.1. Unscrew six external Torx screws (E10, M6 x 25) and remove coolant guide.
26.2. Check moulded seals and replace if necessary.
Lower coolant guide
27. Remove coolant pipes -2- at the coolant distributor -1-.
27.1. Unscrew two external Torx screws (E10, M6 x 25) at the distributor.
Coolant distributor and connecting pipes
27.2. Pull distributor up and off.
O-rings for connecting pipes for coolant distributor
27.3. Replace O-rings -1-.
28. Remove coolant pipe -1- for the coolant regulator housing.
28.1. Unscrew external Torx screw (E10, M6 x 12) -2-. Pull coolant pipe out of the coolant regulator housing.
Coolant connecting tube to thermostat housing
28.2. Unscrew one external Torx screw (E10, M6 x 50) -3- at the coolant regulator housing.
Thermostat housing
29. Loosen bracket -1- for coolant pump.
29.1. Unscrew three external Torx screws (E10, M6 x 25) -1- on the connecting tube for the coolant regulator housing.
Connecting tube from coolant regulator housing to coolant pump
29.2. Turn the belt tensioner clockwise at the hexagon (a/f 30) and secure with an M8 screw -2- or a pin (8 mm).
29.3. Unscrew two external Torx screws (E12) M8 x 50 -3- and one M10 x 65 hexagon-head bolt (a/f 16) -4-.
29.4. Unscrew one external Torx screw (E10) M6 x 20 -5- and one (E12) M8 x 25 -6-.
29.5. Pull off bracket.
Bracket for coolant pump and belt tensioner
30. Remove unit carrier and coolant regulator housing.
30.1. Unscrew two external Torx screws (E12) - one M8 x 35 -1- and one M8 x 50 -2- - at the unit carrier.
Coolant distributor housing screws
30.2. Remove coolant regulator housing and unit carrier together, then pull the unit carrier off the coolant regulator housing.
31. Remove oil filler neck.
31.1. Unscrew external Torx screw (E10, M6 x 12) -2- on the holder.
31.2. Unscrew two external Torx screws (E10, M6 x 20) -1- on the crankcase flange.
31.3. Pull out oil filler neck.
31.4. Replace O-rings.
Threaded joint securing oil filler neck to crankcase
32. Remove oil/water heat exchanger.
-> 174019 Removing and installing oil/water heat exchanger 174019 Removing and installing oil/water heat exchanger.
32.1. Open four spring band clamps -1- for the coolant hoses and hydraulic lines.
Hose connections for heat exchanger
32.2. Pull off hydraulic lines and coolant hoses.
32.3. Unscrew six internal Torx screws (T30, M6 x 20) at the oil/water heat exchanger.
32.4. Remove oil/water heat exchanger.
33. Remove secondary-air pump.
-> 266519 Removing and installing secondary-air pump Service and Repair.
33.1. Remove connector clip for cable plug.
33.2. Unscrew two external Torx screws (E10, M6 x 20) at the cylinder head and one M6 x 25 -2- on the line bracket for cylinder bank 1-3.
33.3. Unscrew one external Torx screw (E10, M6 x 20) at the cylinder head and one M6 x 25 -3- on the line bracket for cylinder bank 4-6.
33.4. Loosen external Torx screw (E12, M8 x 35) on the knock sensor for cylinder bank 1-3 and turn the knock sensor slightly.
33.5. Unscrew three external Torx screws (E10, M6 x 30) -1- on the bracket for the secondary-air pump.
33.6. Carefully remove secondary-air pump with lines for bank 1-3 and bank 4-6.
Secondary-air pump
34. Remove starter.
-> 276019 Removing and installing starter.
34.1. Unscrew two external Torx screws (E14, M10 x 35) at the starter.
34.2. Remove the starter by pulling it towards the belt side.
Information
- The bracket for the oil/water heat exchanger must not be removed at an angle or levered off at one side. This can break the aluminium supports in the crankcase.
35. Remove bracket for oil/water heat exchanger.
-> 176719 Removing and installing bracket for oil cooler 176719 Removing and installing bracket for oil cooler.
35.1. Pull the bracket up and out.
Preliminary work for engine MA.121
NOTICE
Dirt and contamination
- Risk of damage to units or components
-> Protect components from dirt and contamination.
-> Clean or replace dirty components.
Information
- All engine repairs must be carried out using only the specified tools.
- Only these tools have been tested and approved.
Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E.) for external Torx, (T.) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
1. Remove the engine.
-> 100119 Removing and installing engine 100119 Removing and installing engine.
2. Support the engine on the engine assembly support.
-> 1001IN Tools for removing units and working on the engine assembly support Tools and Equipment.
3. Drain engine oil.
3.1. Unscrew oil drain plug and collect engine oil.
3.2. Screw in and tighten screw with new seal.
=> Tightening torque: 50 Nm (37 ftlb.)
4. Remove engine carrier -1-.
4.1. Unscrew four hexagon-head bolts (a/f 16): one M10 x 35 -2- , one M10 x 65 -3- , one M10 x 115 -4- and one M10 x 135 -5-.
4.2. Remove engine carrier.
Engine carrier screws
5. Remove intake-air distributor completely.
-> 244619 Removing and installing intake-air distributor Service and Repair.
5.1. Unclip engine-compartment sensor and rubber sleeve. Disconnect two cable plugs for the control valves and pull cable clip out of the intake-air distributor for cylinder bank 1-3.
5.2. Unscrew one M6 x 16 Torx screw -1- for the air-conditioning line holder. Remove holder and rubber.
Removing holder for refrigerant lines
5.3. Disconnect positive crankcase ventilation lines at the oil separator and resonance tube and unclip them at the cable duct.
5.4. Cable plugs for engine wire harness on cylinder bank 4-6: Unclip tank vent, coolant temperature sensor, solenoid valve and tank vent line.
5.5. Unscrew one external Torx screw (M6 x 12) for each cable duct.
5.6. Unscrew six external Torx screws (E10, M6 x 35) for each intake-air distributor 4-6 and 1-3.
5.7. Completely remove the intake manifold. Pull off vacuum lines.
6. Overview of components on belt side (removal steps described below).
Component overview on belt side
7. Loosen three external Torx screws (E10, M8 x 12) on the hydraulic pump pulley (do not unscrew fully).
8. Remove the drive belt.
-> 137819 Removing and installing drive belt Service and Repair.
9. Remove pulley for hydraulic pump by unscrewing three M8 external Torx screws.
10. Expose oxygen sensor cable (exhaust manifold was already removed when you removed the engine).
Oxygen sensor cable (view of cylinder bank 1-3)
11. Remove heat shields. The upper parts do not have to be unscrewed separately.
11.1. Unscrew four external Torx screws (E10, M6 x 12) -1-.
11.2. Remove heat shields.
Screws on heat shield
Information
- Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire harness).
- -> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine.
12. Disconnect various connectors on the engine wire harness.
-> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine.
12.1. Pull off the following cable plugs:
- Camshaft adjustment (2x)
- Valve lift adjustment (2x) -3-
- Hall sender (2x) -4-
- Coolant temperature sensor
- Knock sensors (2x)
- Secondary-air pump
- Generator
- Air conditioning compressor
- Oil pressure control valve
- Ignition coils (6x) -1-
- Sensor for oil pressure and oil temperature
- Oil level sensor
Overview of cable plugs and cable routing on cylinder head cover
12.2. Unscrew two internal Torx screws (T40, M6 x 12) -2- on the ground cables for the bar ignition modules for each cylinder bank.
12.3. Unscrew one external Torx screw (E12, M8 x 16) -1- on each cable duct for cylinder bank 1-3 and 4-6.
Cable duct screws
12.4. Unclip cable duct on cylinder bank 1-3 and 4-6 towards the belt side.