Overhaul
WM 100331 Converting short engine
Preliminary work
Preliminary work
1. Remove engine.
2. Remove engine from transmission.
3. Secure engine on assembly support.
Information
Component overview
Overview of short engine
Converting short engine
Converting short engine
Caution:
Chips and abrasion cause engine damage!
- Flawless components from used engines with bearing damage, piston seizure or other serious damage must be cleaned thoroughly once disassembled if they are to be reused - parts washing machine.
- Oil/water heat exchangers must be replaced if the above-mentioned damage exists.
- Change engine oil with oil filter.
Caution:
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
- Components must have reached at least 17°C throughout.
- Components must not be too hot (distortion).
- Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.
Information:
In order to convert the engines, ideally two assembly supports should be used for the old and the new engine.
For detailed information and tightening specifications, refer to the corresponding repair instructions.
1. Disassemble old engine in the same way down to the basic state of the short engine. Clean disassembled components.
1.1. Remove wire harness for engine.
1.2. Remove the generator.
1.3. Remove power-steering pump.
1.4. Remove starter.
1.5. Remove knock sensors.
1.6. Remove cylinder heads.
1.7. Remove water pump.
1.8. Remove coolant regulator.
1.9. Remove guide and tensioning rails.
2. Remove coolant guide. To do this, remove 10 screws. -arrows-
Coolant pipe
Component overview for coolant guide
Coolant guide
1 - Distributor pipe
2 - Temperature sensor
3 - Sealing ring
4 - Screw plug - Tightening torque: 30 Nm (22 ftlb.)
5 - Fastening screws on distributor pipe - Tightening torque: 10 Nm (7.5 ftlb.)
6 - Gasket; replace
7 - Sealing ring; check and replace if necessary
8 - Coolant pipe
3. Remove coolant guide and seals. Clean sealing surfaces.
4. Clean components.
5. Inspect components, replace defective components.
6. Check that dowel sleeves and studs are present.
Information on removing and installing the vibration balancer on the removed unit
Warning:
Risk of damage to the engine and danger of crushing if the engine tips over
When removing and installing the vibration balancer with the engine removed (engine on assembly support), excessive use of force can cause the assembly mounting to become kinked.
- The engine must be supported at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block. This applies to all engines and assembly mountings.
Supporting engine (illustration shows V8 engine supported on the assembly support)
Completing short engine
Caution:
Consequential damage caused by defective old parts!
- Components taken from the old engine must be cleaned and checked for signs of damage.
- Damaged components must not be installed on the short engine. They must be replaced.
- Peripheral parts in the old vehicle, such as lines or hoses, must be replaced if damaged.
1. Perform a visual inspection to ensure that the short engine is complete and the sealing faces are in perfect condition.
2. Fit a new oil pump.
3. Install starter.
Installing starter
Figure shows knock sensor on bank 1 - 4
Figure shows knock sensor on bank 5 - 8
4. Fit knock sensors. Align the knock sensors as shown in the illustration and tighten knock sensors - Tightening torque: 23 Nm (17 ftlb.).
5. Install thermostat housing. Fit a new O-ring at the water pump inlet and then insert the thermostat housing. Tighten the two screws - Tightening torque: 10 Nm (7.5 ftlb.).
6. Mount cylinder heads. To do this, turn the engine on the assembly support so that the required cylinder bank is pointing vertically upwards.
7. Fit new cylinder-head gasket. The gasket designation is shown on the back and is legible from above when fitted correctly.
Cylinder bank 1 - 4
Cylinder bank 5 - 8
8. Fit cylinder head. The fastening screws must be tightened in the sequence shown below. The tightening sequences and step-by-step tightening torques must be observed!
Tightening sequence for cylinder head
9. Fit camshaft housing. Apply a bead of liquid sealant 000.043.204.58 (status 02/06, for details of current sealant, see Parts Catalogue) -A- as shown. Then screw two thin centering pins 9321 into two opposing blind holes in the cylinder head. Insert the O-ring -B- into the oil duct. Wipe off any sealant -C- that emerges as a result of screwing.
Applying sealant
10. Position camshaft housing and then unscrew the two centering pins.
11. Tighten the camshaft housing screws in the sequence shown. Don't forget the two hexagon socket head bolts at the front of the camshaft housing.
Tightening sequence for camshaft housing
Screws at the front
12. Install camshafts.
Positioning camshafts
1 - Cam position, cylinder 6
2 - Cam position, cylinder 2 (A) and cylinder 3 (B)
D - Camshaft, cylinder bank 5.8 exhaust side
C - Camshaft, cylinder bank 5.8 intake side
B - Camshaft, cylinder bank 1.4 intake side
A - Camshaft, cylinder bank 1.4 exhaust side
13. Fit oil return line to camshaft housing 5 - 8. Fit oil return line -1- with a new O-ring -2-. Tighten the four screws - Tightening torque: 10 Nm (7.5 ftlb.) -3 and 4- (camshaft housing, cylinder head, crankcase and oil pan).
Oil return line
14. Fit oil feed housing of intake camshaft and tighten screws - Tightening torque: 10 Nm (7.5 ftlb.).
15. Replace the diamond washer and fastening screw located underneath the camshaft adjuster and camshaft timing gear.
Diamond washer
16. Fit deflection rail -4-.
Deflection rail
17. Install camshaft change-over valves - Tightening torque: 10 Nm (7.5 ftlb.). Figure shows procedure with timing-case cover fitted.
Fastening screw for camshaft change-over valve
18. Fit timing drive mechanism. Fit guide rail of cylinder bank 5 - 8. Tighten the leaf spring of the oil pump tensioning rail at the same time.
19. Fit tensioning rail to cylinder bank 1 - 4.
20. Install timing chain. Position the chain on the crankshaft gear wheel and then fit it over all four camshaft timing gears. To do this, use both hands to carefully insert the camshaft adjuster and camshaft timing gear into the timing chain. Screw in fastening screws of the timing gears loosely to half a turn. Figure shows procedure with timing-case cover fitted. Screw in fastening screws of the timing gears loosely to half a turn.
Installing timing chain
21. Fit U-rail. Insert the U-rail into the timing drive mechanism from above. Tighten the four fastening screws.
22. Fit the short guide rails between the camshaft timing gears. Figure shows assembly with timing-case cover fitted.
Guide rails
23. Fit timing-case cover.
24. Place sealing ring over crankshaft using assembly sleeve.
Sealing ring with assembly sleeve
25. Tighten the two upper fastening screws (M6 x 50) and the lower fastening screws (M6 x 12) by hand.
Crankshaft sealing ring
26. Tighten the two upper fastening screws (M6 x 50) and then the lower fastening screws (M6 x 12) by hand. Then tighten the screws crosswise. - Tightening torque: 10 Nm (7.5 ftlb.)
Crankshaft sealing ring
27. Pull assembly sleeve evenly off the sealing ring.
Assembly sleeve
28. Fit crankshaft pulley.
Crankshaft pulley
29. Fit oil pan.
Measurement on the oil pan
30. Fit drive plate or flywheel.
31. Install chain tensioner with new sealing ring. - Tightening torque: 60 Nm (44 ftlb.)
Installation position of chain tensioner
32. Set the timing.
33. Install the camshaft housing cover on both cylinder banks.
34. Fit water pump.
35. Fit engine carrier -5-.
Removing and installing engine support
1 - Nut - Tightening torque: 75 Nm (56 ftlb.)
2 - Bracket for auxiliary units, left
3 - Screw, 10 ea. - Tightening torque: 65 Nm (48 ftlb.)
4 - Hydraulic mount, left
5 - Engine carrier
6 - Screw, 4 ea. - Tightening torque: 60 Nm (44 ftlb.)
7 - Hydraulic mount, right
8 - Engine carrier
9 - Screw, 6 ea. - Tightening torque: 65 Nm (48 ftlb.)
36. Fit power-steering pump.
37. Fit generator.
38. Fit wire harness for engine.
39. Add engine number from old engine on new engine. Carefully imprint or punch in the number.
Subsequent work
Subsequent work
1. Refit engine on transmission.
2. Install engine.