Assembling the Engine
Assembling the engine
Assembly
Assembling the engine
Notice
Dirt and contamination
- Risk of damage to units or components
- Protect components from dirt and contamination.
- Clean or replace dirty components.
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. Fit crankcase half 4-6 on the engine assembly support.
1.1. Use mounting parts 9590 to secure to the engine adapter 9771.
Information
- The bearing shells must be allocated according to specifications.
- Observe difference between partial-groove bearings and smooth bearings.
- Coat bearing shells with new engine oil.
Information
Always replace gaskets and O-rings.
- Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).
2. Fit new bearing shells on the crankcase halves. The following markings ensure correct allocation.
2.1. Crankcase half 4-6: Markings on crankshaft. The upper series of letters -1- is for the crankcase. Allocation starts at the supporting mount (-SL-) on the belt side and is read from left to right. The supporting mount does not have a number, while the main bearings are numbered -HL 1-7- (number 7 is at the flywheel side).
Marking for bearing shell allocation on the crankshaft
G - Bearing shell, Yellow
R - Bearing shell, Red
B - Bearing shell, Blue
2.2. Crankcase 1-3: Markings on crankcase half. The series of letters -1- is read from left to right. Allocation starts at the flywheel side and ends at the supporting mount on the belt side.
G - Bearing shell, Yellow
R - Bearing shell, Red
B - Bearing shell, Blue
Marking on crankcase half 1-3
2.3. There are also different types of bearing shells.
Bearing shells fitted on crankcase
1 - Partial-groove bearing shell
2 - Smooth bearing shell
2.4. Fit and grease new O-ring on the crankcase sealing face.
3. Insert two thrust washers -1- on the main bearing. The oil grooves must be facing outwards.
Thrust washer on crankshaft
Position of grooves on thrust washer
Information
- Check guide and tensioning rails for visible and obvious signs of wear before installation and replace if damaged.
- The tensioning rails on cylinder bank 1-3 and 4-6 are identical.
- The guide rails on cylinder bank 1-3 and 4-6 are identical.
- The slots in the cylinder head must be positioned during installation.
4. Install tensioning rail for oil-pump drive chain in crankcase 4-6.
Tensioning rail for oil-pump timing chain
1 - Rail
2 - Tensioning spring
4.1. Fit tensioning rail -1- using a short bearing pin.
- Tightening torque: 10 Nm (7.5 ft lb.)
Tensioning rail for oil-pump drive in crankcase
Position of bearing pin -4- on tensioning rail for oil-pump drive chain.
Bearing pins on cylinder bank 4-6
5. Fit guide rail for cylinder bank 4-6 and secure in the crankcase with a short bearing pin -2-.
- Tightening torque: 10 Nm (7.5 ft lb.)
5.1. Place spring -2- on tensioning rail -1- for oil-pump drive chain into the cut-out in the guide rail -3-.
Position of tensioning spring in guide rail
6. Insert crankshaft with timing chains -2 + 3-.
6.1. Engage oil pump gear -1- in the drive chain.
Inserting crankshaft into crankcase half 4-6
7. Fix crankshaft in place using special tool holding bridge 9779 -1-.
7.1. Fit and tighten two fastening screws hand-tight.
Crankshaft holding bridge (9779)
8. Install pistons on cylinder bank 4-6 and connecting rods 1-3.
9. Fit 14 through-bolt screws (E14, M10 x 195) -1- with new sealing washers -3-.
9.1. Fit protective sleeve 9786 -2- over the screw thread. Slide sealing washer onto the screw. Remove protective sleeve.
Through-bolt screw, sealing washer and protective sleeve
Information
- The sealing faces of the crankcase halves must be completely free of oil, grease and burrs before applying sealant.
- Apply a bead of sealant with a diameter of no more than 1 mm. Always apply sealant to the required area only.
- Join the crankcase halves within max. 5 minutes of applying the bead of sealant.
10. Apply sealing compound to crankcase half 4-6. Observe processing instructions.
10.1. Use Dobotech sealing compound (Part No. 000.043.207.31).
10.2. Carefully apply a continuous bead of sealant -arrow 1- with a diameter of 1 mm. Follow sealant contour as shown in illustration.
10.3. Remove residual silicone in the crankshaft flange area following installation -arrow 2-.
Applying sealant on crankcase half 4-6
11. Fit rubber sleeves on connecting rods 1-3 (assembly aid 9795) and position vertically.
11.1. The restraining straps P221 can be used if necessary. Since only two connecting rods can be fixed in place in this case, the third connecting rod must be held when positioning the crankcase half.
12. Check guide rail -1- for the oil-pump drive chain on crankcase half 1-3.
Guide rail for oil-pump drive chain
12.1. Replace guide rail -1- in the event of visible or obvious damage.
This can be unclipped and clipped in again -arrows-.
Removing and installing guide rail for oil-pump drive chain
Information
- Get another person to help you join crankcase halves 1-3.
13. With the help of a second person, place crankcase half 1-3 on crankcase half 4-6.
14. Fit 14 through-bolt screws and tighten according to the specified tightening torque and sequence.
14.1. - Initial tightening: 5 Nm (3.5 ft lb)
14.2. - Initial tightening: 12 Nm (9 ft lb.)
14.3. - Tightening torque: 15 Nm (11 ft lb.)
14.4. - Torque angle: 75°
14.5. - Final tightening - torque angle: 75°
Through-bolt screws on crankcase
1-14 - External Torx screw M10 x 1.5 x 195 with sealing washer
15. Fit 19 external Torx screws (E10 and E12) for the outer cross bolt connection and tighten according to the specified tightening sequence.
15.1. Three M8 x 35 screws, position -15, 16, 17-. - Initial tightening: 5 Nm (3.5 ft lb.)
- Torque angle: 70°
15.2. One M8 x 120 screw, position -33-.
- Tightening torque: 33 Nm (24 ft lb.)
15.3. 15 screws - one M6 x 40 -18-, 14 M6 x 25 -19-32-.
- Tightening torque: 13 Nm (9.5 ft lb)
Outer cross bolt connection
16. Screw in and tighten two mounting parts 9590 for bolting crankcase half 1-3 to the engine support.
17. Install pistons for cylinder bank 1-3.
18. Turn the crankshaft clockwise a number of times at the vibration damper using turning device 9773 in order to check for smooth operation and correct function.
18.1. Then, turn the crankshaft so that none of the pistons are at TDC position.
19. Fit crankshaft sealing rings at the flywheel and drive side.
20. Fit tensioning rail for cylinder bank 4-6 using a long bearing pin -3-.
Bearing pins on cylinder bank 4-6
20.1. Fit tensioning rail for cylinder bank 1-3.
20.2. Secure guide rail for cylinder bank 1-3 in the crankcase with a long bearing pin -1-.
Bearing pins on cylinder bank 1-3
20.3. Tighten bearing pins to the specified torque: 10 Nm (7.5 ft lb.).
21. Fit the oil guide (oil plate) -1- using six external Torx screws M6 x 20 -2-.
- Tightening torque: 13 Nm (9.5 ft lb.)
Oil guide (oil plate) on crankcase
22. Install oil pump.
23. Install coolant pipe -1- for the coolant pump.
23.1. Fit and tighten two external Torx screws (E10, M6 x 12) -2-.
- Tightening torque: 13 Nm (9.5 ft lb.)
Coolant pipe for coolant pump
24. Install the oil pan.
25. Insert 12 displacement bodies -1- on cylinder bank 1-3.
Piston marking and displacement bodies on cylinder bank 1-3
Information
- Always guide timing chains with your hand when turning the crankshaft.
26. Fit cylinder head 1-3 and 4-6.
27. Pull timing chain 1-3 out of the chain slot and fit oil supply valve for vacuum pump -1- on the cylinder head with a new O-ring -2-.
Engage timing chain at the valve.
Oil supply valve on vacuum pump for brake booster
28. Hold the tensioning rail for cylinders 1-3 -1- using a pair of flat-nosed pliers -3- and use a socket-wrench insert -4- to screw in the bearing pin -2-.
Guide and tensioning rails
28.1. Secure guide rail for cylinders 4-6 in the cylinder head with a short bearing pin.
28.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ft lb.).
29. Check installation position of tensioning rail for oil-pump drive chain and guide rail again.
Tensioning rail for oil-pump drive chain and guide rail
1 - Tensioning spring for tensioning rail
2 - Guide rail
30. Install solenoid hydraulic valves with new O-rings for camshaft control.
30.1. Tighten two external Torx screws (E8) M5 x 12 on each valve.
- Tightening torque: 8 Nm (6 ft lb.)
31. Install camshafts.
32. Install cylinder head cover.
33. Fit cover for positive crankcase ventilation and gaskets.
33.1. Fit cover for cylinder bank 1-3 -1- with new gaskets -2 + 3- and secure with three external Torx screws M6 x 20 -4-.
Cover on positive crankcase ventilation 1-3
33.2. Fit cover for cylinder bank 4-6 -1- with a new O-ring -2- and secure with two external Torx screws M6 x 20 -3-.
Cover on positive crankcase ventilation 4-6
34. Fit spark plugs.
35. Install ignition coils.
Subsequent work
Notice
Dirt and contamination
- Risk of damage to units or components
- Protect components from dirt and contamination.
- Clean or replace dirty components.
Information
Always replace gaskets and O-rings.
- Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).
1. Install upper coolant distributor housing (unit carrier) -1-.
Unit carrier (installed)
1.1. Fit coolant connection piece using three external Torx screws (E12, M8 x 70) -2-.
1.2. Fit unit carrier using two external Torx screws (E12): one M8 x 50 screw -3 (right)- and one M6 x 35 screw -4-.
1.3. Secure coolant pipe for the unit carrier -1- to the cylinder head using two external Torx screws (E10, M6 x 12) -2-.
- Tightening torque: 13 Nm (9.5 ft lb.)
Coolant pipe with hose and connection piece
2. Fit bracket for coolant pump -1- with new O-rings -2 + 3-.
O-rings for coolant pipes at coolant pump
2.1. Fit one M10 threaded bolt (engine carrier mounting) -7- (using two M10 lock nuts).
- Tightening torque: 5 Nm (3.5 ft lb.)
2.2. Fit the bracket using four external Torx screws. one M8 x 70 (E12) -3-, one M8 x 50 (E12) -4-, one M6 x 20 (E10) -5- and one M8 x 25 (E12) -6-.
Bracket for coolant pump
3. Install housing for coolant regulator.
3.1. Fit housing on the unit carrier and secure to the connecting tube for the coolant pump using three external Torx screws (E10, M6 x 25).
3.2. Fit one external Torx screw (E10) M6 x 50.
3.3. Tighten screws in sequence. - Tightening torque: 13 Nm (9.5 ft lb.)
- Tightening torque: 13 Nm (9.5 ft lb.)
4. Tighten fastening screws on coolant pump bracket and unit carrier.
4.1. - Tightening torque: 33 Nm (24 ft lb.)
4.2. - Tightening torque: 23 Nm (17 ft lb.) Coolant pump bracket
- Tightening torque: 13 Nm (9.5 ft lb.)
4.3. Turn the belt tensioner clockwise as far as it will go at the hexagon (a/f 30). Remove screw from the crankcase bore and allow the belt tensioner to slide back to normal position.
5. Fit vibration damper. Secure with a locating pin (8 mm) for countering purposes.
5.1. Fit and tighten six external Torx screws (E12) M8 x 1 x 25 (fine thread).
- Tightening torque: 60 Nm (44 ft lb.)
6. Fit lower parts of heat shield using external Torx screws (E10) M6 x 12.
- Tightening torque: 10 Nm (7.5 ft lb.)
7. Turn the engine so that the oil pan is at the top.
8. Install coolant pipe -1- for the coolant regulator housing and secure with one external Torx screw (E10, M6 x 12) -2-.
- Tightening torque: 13 Nm (9.5 ft lb.)
Coolant connection pipe to thermostat housing
9. Fit holder for rear silencer using four external Torx screws (E12, M8 x 20).
- Tightening torque: 23 Nm (17 ft lb.)
10. Fit exhaust manifold with new seals. Fit and tighten nine external Torx screws (E12, M8 x 21) from the inside out.
- Tightening torque: 23 Nm (17 ft lb.)
11. Turn the engine 180° at the assembly support.
12. Install coolant distributor. Coat new O-rings -1- with Kluber Gel.
12.1. Fit coolant distributor into coolant pipes.
O-rings for connecting pipes for coolant distributor
12.2. Fit coolant distributor -1- using two external Torx screws (E10, M6 x 25) -2- and tighten screws.
Coolant distributor
- Tightening torque: 13 Nm (9.5 ft lb.)
13. Fit fuel collection pipes -2- and injectors.
- Tightening torque: 13 Nm (9.5 ft lb.)
Screws on fuel collection pipe
14. Install the starter.
15. Install bracket for oil/water heat exchanger -1- with new O-rings.
Fit and tighten seven external Torx screws (E10): five M6 x 45 screws -2- and two M6 x 60 screws -3-.
- Tightening torque: 13 Nm (9.5 ft lb.)
15.1. Pull out stoppers and fit and grease new O-rings -4-.
Bracket for oil/water heat exchanger
16. Install oil/water heat exchanger -1-.
Fit and tighten six internal Torx screws (T30) M6 x 20 -2-.
- Contact force: 13 Nm (9.5 ft lb.)
Oil/water heat exchanger
17. Install oil separator -1- with new O-rings.
17.1. Grease O-rings, fit oil separator and secure with two external Torx screws (E10, M6 x 25) -2-.
- Tightening torque: 13 Nm (9.5 ft lb.)
Oil separator
18. Install high-pressure pump.
19. Fit fuel lines -2 + 4- to high-pressure pump.
19.1. Grease thread with OKS 1700 lubricant (Part No. 000.043.207.36) and tighten union nuts.
19.2. Fit line bracket using M6 external Torx screws -3 + 5-.
19.3. First tighten the union nuts, then the screws on the line bracket.
- Tightening torque: 20 Nm (15 ft lb.)
- Tightening torque: 13 Nm (9.5 ft lb.)
Fuel lines for high/low-pressure connection
20. Install coolant regulator with housing cover -1- and intake tube -5-.
20.1. External Torx screws (E10) on housing cover: Tighten three M6 x 50 screws -3- and one M6 x 40 screw -2-.
20.2. Grease new O-rings on the intake tube and fit tube into the coolant regulator housing. Tighten external Torx screws M6 x 12 -4-.
20.3. - Tightening torque: 13 Nm (9.5 ft lb.)
Intake tube and coolant regulator housing
21. Install vacuum pump for brake booster.
22. Install vacuum line.
23. Install hydraulic pump with reservoir.
24. Install air conditioning compressor.
25. Install B+ wire harness (engine).
26. Fit engine wire harness.
26.1. Secure cable duct to cylinder head 1-3 and 4-6 using one external Torx screw (E12, M8 x 16) on each.
- Tightening torque: 23 Nm (17 ft lb.)
27. Fit fuel connection line (high-pressure side) to fuel collection pipe.
27.1. Grease thread with OKS 1700 lubricant and tighten threaded connections -1 to 5- according to tightening sequence.
- Tightening torque: 20 Nm (15 ft lb.)
- Tightening torque: 13 Nm (9.5 ft lb.)
Tightening sequence for connecting line
28. Fit coolant hoses -2- to oil/water heat exchangers.
28.1. Coat hoses with Kluber Gel and fit them. Close two spring band clamps -1-.
Coolant hoses on heat exchanger
29. Install the generator.
30. Install oil filler neck -1-.
30.1. Grease new O-ring and fit oil filler neck on crankcase.
30.2. Tighten two external Torx screws (E10, M6 x 20) -2-.
- Tightening torque: 13 Nm (9.5 ft lb.)
Oil filler neck
31. Install positive crankcase ventilation line -1-.
31.1. Grease two new O-rings and fit line to bracket for oil/water heat exchanger. Tighten external Torx screw (E10, M6 x 20) -2-.
31.2. Clip in line at two places and fit rapid-action couplings on cylinders 1-3, cylinders 4-6 and on the oil filler neck -3-.
Positive crankcase ventilation line
32. Route coolant vent line from the coolant distributor to the belt side via the fuel connection line and crankcase vent line.
33. Install intake-air distributor.
33.1. Fit complete intake-air distributor and position it on the cylinder heads.
33.2. Fit six external Torx screws (E10, M6 x 35) on each and tighten according to the specified tightening sequence.
- Tightening torque: 13 Nm (9.5 ft lb.)
Tightening specifications (view of 3.8-liter engine)
34. Fit tank vent valve on holder and attach rapid-action coupling to resonance tube.
34.1. Plug in cable plugs on intake-air distributor for cylinder bank 1-3. Tighten one external Torx screw (E10, M6 x 12) -2- used to secure the cable duct.
- Tightening torque: 13 Nm (9.5 ft lb.)
Cable plugs on intake-air distributor 1-3
1 - Cable plug on engine compartment temperature sensor
2 - Cable duct mounting on cylinder bank 1-3
3 - Cable plug on control valve for tank ventilation
35. Only for 3.8-liter engine: Plug in cable plug -1- and attach vacuum line -2- on control valve for tuning flap.
Control valve for tuning flap
36. Fit oil filler neck to holder. To do this, tighten three external Torx screws (E10, M6 x 12) -2-.
- Tightening torque: 13 Nm (9.5 ft lb.)
Oil-fill pipe holder and positive crankcase ventilation line
36.1. Unclip positive crankcase ventilation line -3- at the oil-fill pipe.
37. Connect positive crankcase ventilation line on the resonance tube -1- and clip it in at the intake-air distributor -arrows-.
Positive crankcase ventilation line on cylinder bank 4-6
37.1. Tighten one external Torx screw (E10, M6 x 12) -2- used to secure the cable duct to intake-air distributor 4-6.
38. Fit hydraulic pump pulley using three external Torx screws (E12, M8 x 12).
39. Install the drive belt.
40. Tighten external Torx screws on hydraulic pump pulley.
- Tightening torque: 23 Nm (17 ft lb.)
41. Fit engine carrier -1- and holder for front silencer -5-.
Engine carrier and holder for front silencer
42. Fit rear silencer.
43. Fit front silencer.
44. Remove the engine from the engine assembly support.
45. Fit flywheel with new screws.
46. Mount the transmission.
47. Install the engine.