Assembling engine

→ 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

Cylinder arrangement

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

   Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
   Air/oil separator and oil suction tube to crankcase	M6 x 20	Tightening torque	10 Nm (7.5 ftlb.)

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  .

   Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
   Oil filter		Tightening torque	25 Nm (19 ftlb.)

5. Fit lower guide and tensioning rail screws.

   Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
   Fastening screw for tensioning rail and guide rail	M6	Tightening torque	10 Nm (7.5 ftlb.)

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

   Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
   Fastening screw for oil pump housing to engine block	M6	Tightening torque	10 Nm (7.5 ftlb.)
   Fastening screw for oil pump housing to engine block	M10	Tightening torque	65 Nm (48 ftlb.)

   Information 

   • Cylinder-head gaskets are identical parts, lay them down with the TOP identification facing upwards. 
8. Fit cylinder head 4-6 → Installing cylinder head .
9. Install flat-base tappets 4-6 → Subsequent work for cylinder head 4-6 .
10. Install camshaft 4-6 → Installing camshafts - cylinders 4-6 .
11. Fit tandem pump.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for tandem pump to engine block	M6 x 30, micro-self-locking	Tightening torque	10 Nm (7.5 ftlb.)

12. Install cylinder head cover 4-6 → Installing cylinder head cover .
13. Fit cylinder head 1-3 → Installing cylinder head .
14. Install flat-base tappets 1-3→ Subsequent work for cylinder head 1-3 .
15. Install camshaft 1-3 → Installing camshafts for cylinders 1-3 .
16. Install cylinder head cover 1-3 → Installing cylinder head cover .
17. Install spark plugs → Installing Spark Plugs .

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Spark plugs	Using new spark plugs	Tightening torque	30 Nm (22 ftlb.)
    Spark plugs	Re-using old spark plugs	Tightening torque	25 Nm (19 ftlb.)

18. Fit support for servo lines.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for servo lines support to engine block	M6 x 12	Tightening torque	10 Nm (7.5 ftlb.)

19. Fit transport eyebolt.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for transport eyebolt to engine block	M6 x 16	Tightening torque	10 Nm (7.5 ftlb)

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

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Brackets for oxygen sensor cable to cylinder head cover	M6 x 12	Tightening torque	10 Nm (7.5 ftlb.)

22. Fit coolant adapter.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for coolant adapter to engine block	M6 x 20	Tightening torque	10 Nm (7.5 ftlb.)

23. Install solenoid hydraulic valves for camshaft adjustment → Installing hydraulic valve for camshaft timing .
24. Install thermostat housing.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for thermostat housing to engine block	M6 x 20	Tightening torque	10 Nm (7.5 ftlb.)

25. Fit coolant pump.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for coolant pump to engine block	M6 x 25, M6 x 30	Tightening torque	10 Nm (7.5 ftlb.)

26. Fit coolant lines.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for coolant lines to engine block	M6 x 16	Tightening torque	10 Nm (7.5 ftlb.)

27. Fit crankshaft pulse sender.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for crankshaft pulse sender to engine block	M6 x 15	Tightening torque	10 Nm (7.5 ftlb.)

28. Fit ignition coils.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for ignition coil to engine block	M6 x 25	Tightening torque	10 Nm (7.5 ftlb.)

29. Fit coolant guide housing.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for coolant guide housing to engine block	M6 x 35, M6 x 20	Tightening torque	10 Nm (7.5 ftlb.)

30. Tiptronic only: Fit clip for guide belt.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for clip for guide belt to engine block	M6 x 12	Tightening torque	10 Nm (7.5 ftlb.)

31. Fit engine mounting.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for engine mounting to engine block	M10 x 120, M10 x 80	Tightening torque	65 Nm (48 ftlb.)

32. Fit crankshaft belt pulley retaining device 9593  .

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for pulley to crankshaft	M16 x 60, 1st stage	Tightening torque	50 Nm (37 ftlb.)
    Screw for pulley to crankshaft	M16 x 60, 2nd stage	Torque angle	90°

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

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for engine ground lead to engine block	M8 x 30	Tightening torque	23 Nm (17 ftlb.)

34. Fit deflection roller.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for deflection roller to engine block	M8 x 60	Tightening torque	23 Nm (17 ftlb.)

35. Fit both hall senders.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for hall sender to cylinder head	M6 x 11	Tightening torque	10 Nm (7.5 ftlb.)

36. Fit flange for positive crankcase ventilation.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for flange for positive crankcase ventilation to cylinder head	M6 x 11, micro-self-locking	Tightening torque	10 Nm (7.5 ftlb.)

37. Install oil pressure sender.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Oil pressure sender to valve cover		Tightening torque	30 Nm (22 ftlb.)	+/-5 Nm (+/-3.5 ftlb.)

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

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Oil-level sensor to crankcase		Tightening torque	20 Nm (15 ftlb.)

40. Fit knock sensors.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for knock sensor to engine block	M8 x 35	Tightening torque	20 Nm (15 ftlb.)	+/-2 Nm (+/-1.5 ftlb.)

41. Fit starter.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for starter to crankcase	M10 x 35	Tightening torque	45 Nm (33 ftlb.)

42. Fit secondary air pump.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for secondary air line/secondary air pump to engine block	M6 x 20	Tightening torque	10 Nm (7.5 ftlb.)

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

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for oil mist collector to engine block	M6 x 20, micro-self-locking	Tightening torque	10 Nm (7.5 ftlb.)

44. Fit oil/water heat exchanger.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for oil/water heat exchanger to engine block	M6 x 16	Tightening torque	10 Nm (7.5 ftlb.)

45. Fit engine wire harness.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for ground lead to engine block	M6 x 12	Tightening torque	10 Nm (7.5 ftlb.)
    Screw for plastic wiring harness guide to engine block	M6 x 12	Tightening torque	10 Nm (7.5 ftlb.)
    Screw for plastic wiring harness guide to engine block	M8 x 20	Tightening torque	23 Nm (17 ftlb.)

46. Fit terminal 50 starter line.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Line collar nut, terminal 50 to starter	M6	Tightening torque	10 Nm (7.5 ftlb.)

47. Fit terminal 30 starter line.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Line collar nut, terminal 50 to starter		Tightening torque	15 Nm (11 ftlb.)

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

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for power-steering-pump support to engine block	M8 x 35	Tightening torque	23 Nm (17 ftlb.)

50. Fit power-steering pump.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for power-steering pump to power-steering pump support		Tightening torque	23 Nm (17 ftlb.)

51. Tighten union nut for servo pressure line.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Union nut for servo pressure line		Tightening torque	24 Nm (18 ftlb.)

52. Fit oil filler neck.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for oil filler neck to engine block	M6 x 11, micro-self-locking	Tightening torque	10 Nm (7.5 ftlb.)

53. Fit generator and deflection roller → Installing the generator .

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for generator to support	M10 x 35, M10 x 145	Tightening torque	45 Nm (33 ftlb.)

54. Fit B+ wire on generator.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Collar nut for B+ wire to generator	M8	Tightening torque	15 Nm (11 ftlb.)

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

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for drive belt cover to crankcase	M6 x 12, micro-self-locking	Tightening torque	10 Nm (7.5 ftlb.)

57. Fit intake-air distributor.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for intake-air distributor to cylinder head	M6 x 35	Tightening torque	10 Nm (7.5 ftlb.)

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

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for support to engine block	M6 x 12, micro-self-locking	Tightening torque	10 Nm (7.5 ftlb.)

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.

    Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
    Screw for pulley to power-steering	pump M8 x 12	Tightening torque	23 Nm (17 ftlb.)