Part 2

WM 100137 Disassembling and assembling engine (Continued)

48. Remove brackets for oxygen sensor cables by unscrewing five Torx screws (M6 x 12) -Arrows-.





Brackets for oxygen sensors 1 - 3





Brackets for oxygen sensors 4 - 6

49. Remove all remaining plastic accessories (clips, supports etc.).
50. Remove transport eyebolt -1- by unscrewing two Torx screws (M6 x 16) -2-.
51. Remove supports -3- by unscrewing one Torx screw (M6 x 12) -4-.





Assembly eye

52. Remove spark plugs.
53. Remove cylinder head cover 1 - 3.
54. Remove camshaft 1 - 3.

Caution:
Interchanged or dirty bucket tappets.
- Damage to engine components.

--> The components have been run in in the fitting bores in the housing, therefore do not interchange them.
--> Absolute cleanliness is essential.

55. Remove flat-base tappet 1 - 3.





Example of laying aside flat-base tappets

56. Remove cylinder head 1-3. Loosen and unscrew 12 Torx screws M10 x 230 from outside to inside on each cylinder head. Lift cylinder head and seal from crankcase.
57. Remove cylinder head cover 4 - 6.
58. Remove camshaft 4 - 6.

Caution:
Interchanged or dirty bucket tappets.
- Damage to engine components.

--> The components have been run in in the fitting bores in the housing, therefore do not interchange them.
--> Absolute cleanliness is essential.

59. Remove flat-base tappet 4 - 6.
60. Remove cylinder head 4 - 6. Loosen and unscrew 12 Torx screws (M10 x 230) from outside to inside on each cylinder head. Lift cylinder head and seal from crankcase.
61. Remove oil pump with housing -1- by unscrewing two hexagon-head bolts (M6 x 80) -2-, two Torx screws (M6 x 20) -3- and (M10 x 100) -4-. Remove housing and ensure that the flange projection of the oil pump drive is not tilted. Replace the two O-rings during installation.





Oil pump with housing

62. Remove all carbon deposits and other residues on all six pistons with a brass brush, which will make the engraved markings -Arrow- visible. In addition, number and mark the pistons in installation position before removal.





View of installation position of pistons

63. Unscrew aluminum screw plug (M27) for the assembly bore (piston pin).
64. Remove lower M6 guide and tensioning rail screws (hexagon socket a/f 5), remove the guide and tensioning rails from the chain spaces.
65. Remove oil filter with special tool release key 9204.
66. Unscrew 13 Torx screws M6 x 20 on the oil pan cover. Tap cover gently on the sides using a plastic hammer, then carefully lift it at the leverage bar --> Lifting the oil pan cover using a plastic-coated mounting lever and remove the oil pan.





Lifting the oil pan cover

67. Remove air/oil separator (swirl pots) and oil suction pipe. To remove each separator, unscrew two M6 x 20 Torx screws and pull out the separator. Unscrew two M6 x 20 Torx screws on the oil suction pipe and remove the oil suction pipe. Replace O-rings during installation.





Components in the oil pan

68. Remove bearing cover for intermediate shaft.

Assembling engine

Assembling 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.

Information:
- All O-rings and seals (shaft seals), micro-encapsulated, coated screws or lock nuts must be replaced.

Information:
- Replace all O-rings and grease shaft seals lightly with Optimol MP3 or Kluber Syntheso Glep.

Information:
- The O-rings for the spark-plug recesses must be replaced.

Information:
- Re-insert flat-base tappets in the fitted bores in which they were positioned before the disassembly. The flat-base tappets have been run in in the fitting bores in the housing and therefore may not be switched.

The engine is assembled in reverse order to the disassembly. Components that are not replaced must be cleaned.

Markings on crankcase:

Engine number





Engine number, example of 3.8 ltr. engine

Cylinder arrangement





Cylinder arrangement

1. Fit bearing cover for intermediate shaft.
2. Fit air/oil separator (swirl pots) and oil suction tube.





3. Install oil pan. Apply a bead of sealant, Loctite 5900, to the cleaned and greased oil pan and secure with 13 Torx screws from the inside out. --> Tightening torque: 10 Nm (7.5 ftlb.)
4. Install new oil filter using special tool oil filter spanner 9204.





5. Fit lower guide and tensioning rail screws.





6. Screw in aluminum screw plug (M27) for the assembly bore (piston pin).
7. Fit oil pump with housing.





Information:
- Cylinder-head gaskets are identical parts, lay them down with the TOP identification facing upwards.

8. Fit cylinder head 4-6.

Caution:
Interchanged or dirty bucket tappets.
- Damage to engine components.

--> The components have been run in in the fitting bores in the housing, therefore do not interchange them.
--> Absolute cleanliness is essential.

9. Install flat-base tappets 4-6.
10. Install camshaft 4-6.
11. Fit tandem pump.





12. Install cylinder head cover 4-6.
13. Fit cylinder head 1-3.

Caution:
Interchanged or dirty bucket tappets.
- Damage to engine components.

--> The components have been run in in the fitting bores in the housing, therefore do not interchange them.
--> Absolute cleanliness is essential.

14. Install flat-base tappets 1-3.
15. Install camshaft 1-3.
16. Install cylinder head cover 1-3.
17. Install spark plugs.





18. Fit support for servo lines.





19. Fit transport eyebolt.





20. Fit all plastic components that have been removed (clips, support, etc.).
21. Fit brackets for oxygen sensor cable.





22. Fit coolant adapter.





23. Fit solenoid hydraulic valves for camshaft adjustment.
24. Install thermostat housing.





25. Fit coolant pump.





26. Fit coolant lines.





27. Fit crankshaft pulse sender.





28. Fit ignition coils.





29. Fit coolant guide housing.





30. Tiptronic only: Fit clip for guide belt.





31. Fit engine mounting.





32. Fit crankshaft belt pulley retaining device 9593.





33. Fit engine ground lead on cylinder 1-3.





34. Fit deflection roller.





35. Fit both hall senders.





36. Fit flange for positive crankcase ventilation.





37. Install oil pressure sender.





38. Coat spacer sleeve with acid-free grease at the base and insert it.
39. Install oil-level sensor.





40. Fit knock sensors.





41. Fit starter.





42. Fit secondary air pump.





43. Fit oil mist collector. Fix hose with spring band clamp.





44. Fit oil/water heat exchanger.





45. Fit engine wire harness.





46. Fit terminal 50 starter line.





47. Fit terminal 30 starter line.





48. Fit positive crankcase ventilation line.
49. Fit power-steering pump support.





50. Fit power-steering pump.





51. Tighten union nut for servo pressure line.





52. Fit oil filler neck.





53. Fit generator and deflection roller.





54. Fit B+ wire on generator.





55. Connect cable plug to generator.
56. Fit cover for drive belt.





57. Fit intake-air distributor.





58. Fit support for servo lines. Clip oxygen sensor line into support.





59. Connect cable plug for carbon canister solenoid valve.
60. Connect cable plug for all fuel injectors.
61. Push on cable plug for engine compartment temperature sensor.
62. Connect cable plug for the solenoid valves.
63. Fit pulley for power-steering pump.





Subsequent work for assembling engine

Assembling engine, touching up

Manual transmission:

1. Install flywheel.
2. Fit clutch.

Tiptronic transmission:

3. Install drive plate for converter.
4. Remove exhaust manifold.
5. Fit transmission.
6. Install engine.
7. Fill in engine oil. Unscrew oil drain plug (hexagon socket a/f 8).