Part 2
WM 1001Z2 Assembling engine
Timing chain and chain guide
38. Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be released).
39. Fit "U"-shaped deflection rail -4-.
Timing chain and sprockets
40. Fit tensioning rail and let it hang.
41. Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
42. Loosely fit camshaft controller and sprockets using screws.
43. Position timing chain and guide correctly over guide and tensioning rails.
44. Fit timing-case cover. Secure sheetmetal holder for tank vent to the upper screw on the timing-case cover at the 1st cylinder. -> 153319 Removing and installing timing-case cover Removal and Replacement; chain tensioner is still removed.
45. Replace and fit joint flange (sealing ring) between the vibration damper and timing-case cover. -> 137419 Removing and installing crankshaft sealing ring for pulley/vibration balancer Service and Repair
46. Turn the engine around. Oil pump is upright.
47. Lay sealing ring in the lower part of the crankcase.
48. Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.
Applying sealant to oil guide housing (4WD)
49. Position oil guide housing and align against transmission or projection of lower part of the crankcase. On the transmission side, the oil guide housing must not project further than the crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil guide housing can be adjusted in the same way as the timing-case cover (using dial gauge, etc.). For details, see -> 175019 Removing and installing oil guide housing 175019 Removing and installing oil guide housing
50. Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence -4-. Don't forget the screws between the oil guide housing and timing-case cover (five screws behind front vibration balancer, bores are currently overhead). -7-
Oil guide housing with accessories
51. Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace sealing rings.
Oil lines on turbo engine
Oil lines on turbo engine, view with oil pan removed
52. Push joint flange of the oil pressure control valve through the side opening in the housing via the oil pressure control valve and secure using two screws -1, 2 and 3-.
53. Fit oil level sensor (turn carefully when inserting sensor). -5 and 6-
54. Fit oil pan with a new seal and tighten evenly and in diagonally opposite sequence.
Oil pan
55. Turn the engine around.
56. Position vibration balancer with screw tightened by hand.
57. Set the timing. Follow procedure exactly. -> 150516 Setting timing for camshafts Procedures
WARNING
Risk of damage to the engine and danger of crushing if the engine tips over
- When removing and installing the vibration damper 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.
58. Tighten vibration balancer -3 and 4- to the specified torque (use a brace brace 9679/1 ). Make a mark between the screw and the vibration balancer using a water-resistant marker (continuous line from screw to vibration balancer). Mark a second line on the vibration balancer at 180° from the first marking. Tighten from first marking to the second marking (torque-angle tightening). For details, see -> 137619 Removing and installing pulley (vibration balancer) Service and Repair
Supporting engine (illustration shows V8 engine supported on assembly support)
Pulleys
59. Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see -> 246319 Removing and installing high-pressure pump Service and Repair
60. Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it. -> 477619 Removing and installing vacuum pump Service and Repair
Vacuum pump
61. Fit spark plugs if necessary. -> 287020 Removing and fitting spark plugs Service and Repair
62. Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see -> 158219 Removing and installing cylinder head cover Service and Repair
63. Fit both eyelets.
64. Move thermostat housing between the two sides of the crankcase into installation position. Tighten three screws (leave one loose for the fuel rail). Grease sealing ring on the small coolant pipe sparingly with Kluber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be pre-fitted and installed complete with the rear coolant pipe.
Thermostat housing and coolant regulator
65. Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50:50 with water) and press them as far as they will go into the thermostat housing. For details, see -> 195819 Removing and installing coolant regulator (thermostat insert) Service and Repair
66. Route boost-pressure control and wastegate lines and fit holder.
Boost pressure and wastegate 2
Boost pressure and wastegate 1
67. Grease both sealing rings on the coolant pipe sparingly with Kluber Syntheso GLEP 1 and press them into the thermostat housing from the rear. Align with screw points on the coolant collection pipe and then screw down!
Coolant guide
68. Fit the water pump. Fit pulley for water pump. For details, see -> 195019 Removing and installing coolant pump Service and Repair
69. Fit oil pressure sensor with adapter. Replace sealing rings.
Oil pressure sensor and oil pressure measuring point
70. On 4WD vehicles, install one cross shaft cover with the cross shaft pipe -1-. Replace sealing rings in the covers.
Cross shaft pipe with cover
70.1. Apply housing seal -2- (Doboseal 224N (999.915.573.43 status 09/09)) to the seating points of the two cross shaft covers close to the edge of the housing.
70.2. Position cross shaft cover with cross shaft pipe -1-.
Make sure that the cross shaft pipe is protruding at a centre position from the opposite opening on the oil guide housing.
The -TOP- marking must be facing upwards.
70.3. Screw in fastening screws -arrows-.
71. Install the second cross shaft cover -1-.
Cross shaft cover
71.1. Position the cross shaft cover -1-.
Make sure that the cross shaft pipe is inserted into the centre opening on the cover.
The -TOP- marking must be facing upwards.
71.2. Screw in fastening screws.
72. Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor -1-.
Left bracket for auxiliary units and 4WD turbo engine mounting
73. Fit front-wheel drive (all-wheel drive) for 4WD vehicles. -> 398819 Removing and installing four-wheel final drive 398819 Removing and installing four-wheel final drive
74. Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position. -> 103519 Removing and installing engine mounting Service and Repair
75. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
Coolant supply on turbo engine
76. Fit the generator and crash support. For details, see -> 272219 Removing and installing generator Service and Repair
Generator
77. Fit deflection rollers and belt tensioner and press on cover.
Belt drive
78. Fit crankshaft sealing ring on flywheel side. See -> 135919 Removing and installing sealing ring for crankshaft (transmission side) Service and Repair
79. Fit coolant hosing and secure clamps.
Coolant return on turbo engine
Coolant supply on turbo engine
80. Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.
Ventilation
81. Roughly position engine wire harness. Place cable duct onto coolant collection pipe and lay both harnesses for the cylinder banks. At the timing-case cover lay them downwards to the generator. Wire up air conditioning compressor, insert injectors, wire up bar ignition modules. Screw down ground points. For details, see -> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine
82. Fit high-pressure line and low-pressure line. To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.
High-pressure pump, turbo engine
83. Fit high-pressure fuel distribution pipe. For details, see -> 243019 Removing and installing fuel distribution pipe Removal and Replacement
84. Check the DFI high-pressure system for leaks. -> 243001 Checking fuel distribution pipe for leaks Testing and Inspection
85. Fit the turbocharger. Fit seals correctly. Observe tightening sequence. It is best to fit the turbocharger to the engine with the lines connected and fitted and then screw it on.
Turbocharger, cylinders 1 to 4 - cooling
Turbocharger, cylinders 5 to 8 - cooling
Oil circuit for turbocharger, cylinders 1 to 4
Oil circuit for turbocharger, cylinders 5 to 8
Turbocharger exhaust manifold, cylinders 1 to 4
Turbocharger exhaust manifold, cylinders 5 to 8
Tightening sequence for turbocharger/exhaust manifold
86. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. => Ventilation on turbo engines
Ventilation on turbo engines
87. Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see -> 244619 Removing and installing intake-air distributor Service and Repair
88. Fit oil mist separator. For details, see -> 105519 Removing and installing oil mist separator Service and Repair.
89. Fit power-steering pump. For details, see installation description -> 489855 Replacing hydraulic pump 489855 Replacing hydraulic pump (PDCC)
90. Fit air conditioning compressor. -> 873419 Removing and installing air conditioning compressor
91. Fit pulley for power-steering pump or tandem pump.
Pulleys
92. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). -> 137819 Removing and installing drive belt 137819 Removing and installing drive belt
93. Fit heat protection panels on generator and on exhaust manifold.
94. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.