1001Z2 Assembling engine
WM 1001Z2 Assembling engine
Tools
Technical values
Assembling 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.
-> 1001IN Tools for removing units and working on the engine assembly support Tools and Equipment.
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
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.
Marking on crankcase half 1-3
2.3. There are also different types of bearing shells.
Bearing shells fitted on crankcase
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.
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
4.1. Fit tensioning rail -1- using a short bearing pin.
=> Tightening torque: 10 Nm (7.5 ftlb.)
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 ftlb.)
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.
-> 131020 Removing and installing pistons and handling tools Service and Repair.
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 ftlb.)
14.2. => Initial tightening: 12 Nm (9 ftlb.)
14.3. => Tightening torque: 15 Nm (11 ftlb.)
14.4. => Torque angle: 75° (56 ftlb.)
14.5. => Final tightening - torque angle: 75° (56 ftlb.)
Through-bolt screws on crankcase
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 ftlb.)
=> Torque angle: 70°
15.2. One M8 x 120 screw, position -33-.
=> Tightening torque: 33 Nm (24 ftlb.)
15.3. 15 screws - one M6 x 40 -18- , 14 M6 x 25 -19-32-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Outer cross bolt connection
16. Fit and tighten two mounting parts 9590 for bolting crankcase half 1-3 to the engine support.
17. Install pistons for cylinder bank 1-3.
-> 131020 Removing and installing pistons and handling tools Service and Repair.
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.
-> 135919 Removing and installing crankshaft sealing ring - flywheel side Service and Repair.
-> 137419 Removing and installing crankshaft sealing ring - belt side Service and Repair.
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 ftlb.).
21. Pull timing chains out of the chain slot.
22. Fit the oil guide (oil plate) -1- using six external Torx screws M6 x 20 -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Oil guide (oil plate) on crankcase
23. Install oil pump.
-> 172019 Removing and installing oil pump Service and Repair.
24. Install coolant pipe -1- for the coolant pump.
24.1. Fit and tighten two external Torx screws (E10, M6 x 12) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Coolant pipe for coolant pump
25. Install the oil pan.
-> 175019 Removing and installing oil pan Service and Repair.
26. 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.
27. Fit cylinder head 1-3 and 4-6.
-> 157019 Removing and installing cylinder head Service and Repair.
28. Fit oil supply valve for vacuum pump -1- and new O-ring -2- on cylinder head 4-6. Engage timing chain at the valve.
Oil supply valve on vacuum pump for brake booster
29. 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-.
Holding tensioning rail
29.1. Secure guide rail for cylinders 4-6 in the cylinder head with a short bearing pin.
29.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ftlb.).
30. 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
31. Install solenoid hydraulic valves for camshaft control with new O-rings.
31.1. Tighten two external Torx screws (E8) M5 x 12 on each valve.
=> Tightening torque: 8 Nm (6 ftlb.)
32. Install camshafts.
-> 150520 Removing and installing camshafts (includes setting timing) Service and Repair.
33. Install cylinder head cover.
-> 158219 Removing and installing cylinder head cover Service and Repair.
34. Fit cover for positive crankcase ventilation.
34.1. 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
34.2. 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
35. Fit spark plugs.
-> 287020 Removing and installing spark plugs Service and Repair.
36. Install bar ignition modules.
-> 282020 Removing and installing ignition coils Service and Repair.
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
- Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93).
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).
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.
1. Fit bracket for oil/water heat exchanger and heat exchanger.
1.1. -> 176719 Removing and installing bracket for oil cooler 176719 Removing and installing bracket for oil cooler.
1.2. -> 174019 Removing and installing oil/water heat exchanger 174019 Removing and installing oil/water heat exchanger.
Component overview of bracket for oil cooler
2. Install the starter.
-> 276019 Removing and installing starter .
3. 2.9-litre engine only:Install secondary-air pump and lines.
-> 266519 Removing and installing secondary-air pump Service and Repair.
-> 266719 Removing and installing secondary-air line Service and Repair.
4. Install oil filler neck.
4.1. Fit oil filler neck with a new O-ring.
4.2. Fit and tighten two external Torx screws (E10, M6 x 20) -1- on the crankcase flange.
4.3. Screw in external Torx screw (E10, M6 x 12) -2- on the holder.
4.4. => Tightening torque: 13 Nm (9.5 ftlb.)
Threaded joint securing oil filler neck to crankcase
5. Overview of components on belt side (installation steps described below).
Overview of components on belt side
6. Fit high-pressure pump -1- and lines -2 + 3-.
-> 246319 Removing and installing high-pressure pump .
6.1. Fit and tighten two external Torx screws (M6 x 25) -6- on the pump.
6.2. Fit support -4- : screw in and tighten two external Torx screws (E10) M6 x 25 -6- at the top and one M6 x 40 -5- at the bottom.
6.3. => Tightening torque: 13 Nm (9.5 ftlb.)
Overview of high-pressure pump components
7. Fit fuel lines to the high-pressure pump.
7.1. Grease thread with OKS 1700 lubricant (Part No. 000.043.207.36) and tighten union nuts.
7.2. Fit line bracket using M6 external Torx screws.
7.3. First tighten the union nuts, then the screws on the line bracket.
=> Tightening torque: 20 Nm (15 ftlb.)
=> Tightening torque: 13 Nm (9.5 ftlb.)
8. Fit vacuum pump on cylinder head 4-6 with lines.
-> 477619 Removing and installing vacuum pump - as of model year 2009 Service and Repair.
-> 477755 Replacing vacuum line for brake booster (section at engine).
8.1. Fit and tighten three external Torx screws (M6 x 20).
8.2. Attach vacuum line for brake booster with new O-ring to the pump and position it at the oil pan.
8.3. Fit and tighten external Torx screws (M6 x 12) on the vacuum line holder.
8.4. => Tightening torque: 13 Nm (9.5 ftlb.)
9. Install upper coolant distributor housing (unit carrier).
-> 195919 Removing and installing coolant distributor housing (unit carrier) - Engine installed 195919 Removing and installing coolant distributor housing (unit carrier) - Engine installed.
Overview of coolant distributor (unit carrier)
10. Secure coolant pipe -1- to the coolant connection piece at the cylinder head using two external Torx screws (E10, M6 x 12) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Coolant pipe with hose and connection piece
11. Install bracket for coolant pump and coolant regulator housing.
-> 195519 Removing and installing housing for coolant regulator 195519 Removing and installing housing for coolant regulator.
Overview of coolant regulator housing with 987 II coolant pump
11.1. Fit bracket for coolant pump -1- with new O-rings -2 + 3-.
O-rings for coolant pipes at coolant pump
11.2. Install coolant regulator housing.
12. Tighten fastening screws on coolant pump bracket and unit carrier.
12.1. => Tightening torque: 33 Nm (24 ftlb.)
12.2. => Tightening torque: 23 Nm (17 ftlb.) Coolant pump bracket
=> Tightening torque: 13 Nm (9.5 ftlb.)
12.3. 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.
13. Install coolant regulator cover.
-> 195519 Remove and install coolant regulator cover 195519 Removing and installing coolant regulator cover.
13.1. Grease moulded seals with Kluber Gel.
13.2. Fit and tighten three external Torx screws (E10, M6 x 50).
13.3. => Tightening torque: 13 Nm (9.5 ftlb.)
14. 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 ftlb.)
Coolant connection pipe to thermostat housing
15. Fit lower coolant guide -1-.
15.1. Grease moulded seals with Kluber Gel.
15.2. Fit and tighten six external Torx screws (E10, M6 x 25) -2-.
15.3. => Tightening torque: 13 Nm (9.5 ftlb.)
Lower coolant guide
16. Fit vibration damper. Secure with a locating pin (8 mm) for countering purposes.
-> 137519 Removing and installing vibration damper Service and Repair.
16.1. Fit and tighten six external Torx screws (E12) M8 x 1 x 25 (fine thread).
=> Tightening torque: 60 Nm (44 ftlb.)
17. Install coolant distributor. Coat new O-rings -1- with Kluber Gel.
17.1. Fit coolant distributor into coolant pipes.
O-rings for connecting pipes for coolant distributor
17.2. Fit coolant distributor -1- using two external Torx screws (E10, M6 x 25) -2- and tighten screws.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Coolant distributor
18. 3.4-litre engine only: Fit fuel collection pipes and injectors.
-> 243019 Removing and installing fuel collection pipe (with fuel injectors) - DFI Service and Repair.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Tightening sequence for fuel collection pipe
19. Install hydraulic pump with reservoir.
-> 489819 Removing and installing hydraulic pump - as of model year 2009 Service and Repair.
20. Install air conditioning compressor.
-> 873419 Removing and installing air conditioning compressor Service and Repair.
21. Install B+ wire harness (engine).
-> 97451900 Removing and installing wire harness for battery wiring 97451900 Removing and installing wire harness for battery wiring.
22. Fit engine wire harness.
-> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine.
22.1. 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 ftlb.)
23. Fit heat shields using external Torx screws (E10, M6 x 12) -1-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
Screws on heat shield
24. 3.4-litre engine only: Fit fuel connection line (high-pressure side) to fuel collection pipe.
-> 243019 Removing and installing fuel collection pipe with fuel injectors Service and Repair.
24.1. Grease thread with OKS 1700 lubricant and tighten threaded connections -1 to 5- according to tightening sequence.
=> Tightening torque: 20 Nm (15 ftlb.)
=> Tightening torque: 13 Nm (9.5 ftlb.)
Tightening sequence for connecting line
25. Fit coolant hoses and hydraulic lines at the oil/water heat exchanger.
25.1. Grease coolant hoses with Kluber Gel and fit them. Connect hydraulic lines while dry.
25.2. Close spring band clamps -1-.
Hose connections for heat exchanger
26. Install the generator.
-> 272219 Removing and installing generator Service and Repair.
27. Install oil separator -1-.
27.1. Fit and tighten two external Torx screws (E10, M6 x 25) -2-.
27.2. => Tightening torque: 13 Nm (9.5 ftlb.)
Oil separator
28. Install positive crankcase ventilation line.
28.1. Grease two new O-rings and fit line to bracket for oil/water heat exchanger. Tighten external Torx screw (E10, M6 x 20).
28.2. Clip in line at two places and fit rapid-action couplings on cylinders 1-3, cylinders 4-6 and on the oil filler neck.
Positive crankcase ventilation line
29. Install intake-air distributor.
-> 244619 Removing and installing intake-air distributor Service and Repair.
29.1. Grease moulded seals with Kluber Syntheso Glep.
29.2. Fit complete intake-air distributor and position it on the cylinder heads.
29.3. 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 ftlb.)
30. Connect positive crankcase ventilation line to the resonance tube and clip it in at the intake-air distributor.
30.1. Tighten external Torx screws (E10, M6 x 12) used to secure the cable duct to the intake-air distributor.
31. Fit hydraulic pump pulley using three external Torx screws (E12, M8 x 12).
32. Install the drive belt.
-> 137819 Removing and installing drive belt Service and Repair.
33. Tighten external Torx screws on hydraulic pump pulley.
=> Tightening torque: 23 Nm (17 ftlb.)
34. Fit engine carrier.
-> 103019 Removing and installing engine carrier 103019 Removing and installing engine carrier.
34.1. => Tightening torque: 46 Nm (34 ftlb.)
Engine carrier screws
35. Remove the engine from the engine assembly support.
-> 1001IN Tools for removing units and working on the engine assembly support Tools and Equipment.
36. Fit flywheel with new screws.
-> 136019 Removing and installing flywheel - PDK transmission 136019 Removing and installing flywheel - PDK transmission.
-> 136019 Removing and installing dual-mass flywheel 136019 Removing and installing dual-mass flywheel.
37. Mount the transmission.
-> 343527 Removing and mounting transmission 343527 Removing and mounting transmission.
-> 373427 Removing and mounting Porsche Doppelkupplung (PDK) 373427 Removing and mounting Porsche Doppelkupplung (PDK).
38. Install the engine.
-> 100119 Removing and installing engine 100119 Removing and installing engine.