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 

Always replace gaskets and O-rings.

Information 

• Always replace lock nuts. 

Information 

For all lubrication points, use Kluber Syntheso Glep (Part No. 000.043.204.68).

1. Install cylinder head.
   1. 1.1. Fit new metal seal (identical part). The "TOP"  marking must be facing you.
   2. 1.2. Fit twelve M10 internal multiple-tooth nuts using a socket wrench 9295  (coat sealing surface with a small amount of oil). Cover intake openings (with adhesive tape for example).
   3. 1.3. Tighten multiple-tooth nuts according to tightening specifications (see table below) and tightening sequence.

   Sequence	Designation	Value	Unit
   Step 1	Initial tightening	30 (22)	Nm (ft. lb.)
   Step 2	Loosen
   Step 3	Joining torque	20 (15)	Nm (ft. lb.)
   Step 4	Subsequent tightening	20 (15)	Nm (ft. lb.)
   Step 5	Final tightening	75 ± 5	Degrees (torque angle)
   Step 6	Final tightening	75 ± 5	Degrees (torque angle)

2. Fit tensioning and guide rails using one pin on each rail.→ Length: 74.5 mm 
   Fig 1: Fitting Tensioning And Guide Rails

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   1. 2.1. Fit tensioning rail with pin with a new sealing ring.
   2. 2.2. Fit guide rail with pin with a new sealing ring.
   3. 2.3. Check that the rails run smoothly and then tighten both pins. → Tightening torque: 31 Nm (23 ft. lb.) 
3. Align chain box with guide and tensioning rails.
4. Install chain box.
   1. 4.1. Screw in five M8 screws: two M8 x 35 screws with washer (on the dowel sleeves), two M8 x 30 screws with washer and one M8 x 25 Torx screw.→ Tightening torque: 23 Nm (17 ft. lb.) 
5. Pull timing chain out of chain slot and secure guide rail to chain box. Insert short pin at the top (length = 69 mm) with a new sealing ring. → Tightening torque: 31 Nm (23 ft. lb.) 
6. Fit new O-rings on aluminum sleeves, grease them (Kuber grease) and insert into the chain box.
7. Insert a new molded seal into the chain box groove and coat with Kluber grease.
8. Install camshaft housing → 150319 REMOVING AND INSTALLING CAMSHAFT HOUSING .
   1. 8.1. Fit new metal seal (observe Left/Right) and carefully position housing (be careful with the O-rings on the aluminum sleeve).
   2. 8.2. Fit 18 screws (M8 x 50), screw in uniformly from the inside out and tighten in two stages according to tightening sequence. → Initial tightening: 23 Nm (17 ft. lb.)  ; → Final tightening: 28 Nm (21 ft. lb.) 
9. Coat fitting bores for bucket tappets with new engine oil.
   NOTE: Interchanged or dirty bucket tappets

   • Scoring on cylinder head

   → Since the bucket tappets have been run in the fitting bores, do not interchange them.

   → Absolute cleanliness is essential.

   NOTE: Interchanged or dirty bucket tappets

   • Scoring on cylinder head

   → Since the bucket tappets have been run in the fitting bores, do not interchange them.

   → Absolute cleanliness is essential.

10. Fit bucket tappets and switchable tappets. Every component (that was already installed) must be refitted at its original position.
11. Coat camshaft bearing surfaces with new engine oil. When installing bearings for the first time, coat them with acid-free grease (Optimol Optipit bearing grease).
12. Install camshafts → 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .
13. Install cover for camshaft housing.
14. Fit spark plugs. → Tightening torque: 30 Nm (22 ft. lb.) 
15. Install ignition coils. → Tightening torque: 10 Nm (7.5 ft. lb.) 
16. Install solenoid hydraulic camshaft control valves and valve lift adjustment valves.
17. Tap four new plastic lids onto the camshaft housing cover using a plastic hammer.
18. Fit covers for intake camshafts using three M6 Torx screws and one holder each.→ Tightening torque: 10 Nm (7.5 ft. lb.)  .
19. Install oil suction pump (side 4-6) and tandem pump (side 1-3). → Tightening torque: 10 Nm (7.5 ft. lb.)  .
    1. 19.1. Replace two small O-rings -1-  and one large O-ring -2-  .
       Fig 2: Identifying Oil Suction Pump

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    2. 19.2. Fit pumps with three M6 Torx screws on each. Also secure a holder to the tandem pump. → Tightening torque: 10 Nm (7.5 ft. lb.) 
20. Install heat exchanger bracket.
    1. 20.1. Fit five new O-rings on the connecting flanges. Coat O-rings with Kluber grease.
    2. 20.2. Apply a uniform bead of sealant (Drei Bond 2210 sealant) to the crankcase sealing face. → Tightening torque: 10 Nm (7.5 ft. lb.) 
    3. 20.3. Fit and tighten four new coated M6 inner Torx screws.
       Fig 3: Identifying Heat Exchanger Bracket

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21. Fit new oil filter. Coat O-ring with Kluber grease. → Tightening torque: 25 Nm (19 ft. lb.) 
22. Fit oil/water heat exchanger. Coat new O-rings with Kluber grease.
    Fig 4: Identifying Oil-Water Heat Exchanger O-Ring Assignment

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    1. 22.1. Fit large oil/water heat exchanger with four new O-rings and secure with four M6 Torx screws. → Tightening torque: 10 Nm (7.5 ft. lb.) 
    2. 22.2. Fit small oil/water heat exchanger with four new O-rings and secure with four M6 Torx screws. Also fit the vent line holder for the turbocharger oil tank on the inside. → Tightening torque: 10 Nm (7.5 ft. lb.) 
23. Position coolant guide housing with oil pump.
    1. 23.1. Grease new O-ring and insert driver into the Torx splines.
    2. 23.2. Fix housing in place on the crankcase with one screw (M10 x 60). This screw must be removed again before fitting the engine strut.
24. Fit coolant hose to heat exchanger bracket using a screw-type clamp.
25. Install secondary unit carrier.
    1. 25.1. Coat coolant hose from the heat exchanger bracket (right side) with Kluber grease and fit to the carrier with a screw-type clamp.
    2. 25.2. Insert four Torx screws (M10 x 60) and tighten only slightly.
26. Tighten screw-type clamp on connection piece for heat exchanger bracket.
27. Install coolant pipes.
    Fig 5: Identifying Coolant Pipes

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    1. 27.1. Replace O-rings on the (four) new sealing sleeves and grease them.
    2. 27.2. Insert sealing sleeve into secondary unit carrier.
    3. 27.3. Loosely fit bottom heating tube with pulse sender holder.
    4. 27.4. Position top heating tube with coolant pipe and coolant hose. Fix connection piece in place on the crankcase using two M6 Torx screws. Clip tube into pulse sender holder.
       Fig 6: Identifying Coolant Lines Screw-Type Clamps

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    5. 27.5. Fit coolant hoses on bottom heating tube and tighten screw-type clamps.
       Fig 7: Identifying Heater And Heat Exchanger Bracket Coolant Connection

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    6. 27.6. Fit right coolant connection piece on the secondary unit carrier. Screw in two Torx screws only slightly on the crankcase.
28. Tighten four Torx screws (M10 x 60) on the secondary unit carrier. → Tightening torque: 65 Nm (48 ft. lb.)  .
    Fig 8: Removing Secondary Unit Carrier

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29. Tighten Torx screws on the coolant pipes. → Tightening torque: 10 Nm (7.5 ft. lb.) 
30. Tighten screw-type clamps on the heater pipelines.
31. Secure heating tubes.
    1. 31.1. Slide on sliding parts for plastic holder for heating tubes.
       Fig 9: Sliding Heating Tubes Holder

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    2. 31.2. Position B+ line and secure holder with two Torx screws (M6 x 55).

       → Tightening torque: 10 Nm (7.5 ft. lb.) 

       Fig 10: Securing Plastic Holder

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32. Secure pulse sender holder to the cylinder head using one M6 x 12 Torx screw. → Tightening torque: 10 Nm (7.5 ft. lb.) 
33. Fit oil supply lines for turbocharger with new O-rings. Tighten one M6 inner Torx screw on each line. → Tightening torque: 10 Nm (7.5 ft. lb.) 
34. Fit engine wire harness with fuel return line to the fuel cooler.
    1. 34.1. Fix wire harness and line in place with two M6 Torx screws. → Tightening torque: 10 Nm (7.5 ft. lb.) 
    2. 34.2. Connect electric connectors for knock sensors, coolant temperature sensor and oil pressure/temperature sensor.
35. Fit power-steering lines for clutch support.
    1. 35.1. Fit lines and clip them into the brackets.
    2. 35.2. Fit lines on power-steering reservoir. Secure return line with a plug-in coupling and pressure line with a union nut. → Tightening torque: 30 Nm (22 ft. lb.) 
36. Fit run-on pump. Fit coolant hose with a screw-type clamp and tighten one Torx screw (M6 x 12) on the holder. Connect cable plug.→ Tightening torque: 10 Nm (7.5 ft. lb.) 
37. Position coolant supply line for turbocharger and fit it to the run-on pump with a spring band clamp.
38. Fit the two turbocharger holders using Torx screws. Also secure the ground cable on side 1-3 (left attachment point).
    Fig 11: Identifying Turbocharger Holder (Side 1-3)

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39. Install generator → 272219 REMOVING AND INSTALLING GENERATOR .
40. Secure holder for oil-filter console using two M6 Torx screws. → Tightening torque: 10 Nm (7.5 ft. lb.)  .
    Fig 12: Identifying Oil-Filter Console Holder

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41. Install air conditioning compressor with fuel cooler. → WM 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .
    1. 41.1. Fit fuel return line on radiator.
    2. 41.2. Tighten union nut for fuel line. It is very important to counter when doing this using an open-ended wrench.
42. Fit oil lines with new O-rings on the suction pump for the engine on side 4-6 and grease O-rings.
    1. 42.1. Fit top line from turbocharger oil tank and then lower line to crankcase.
    2. 42.2. Fit bottom line on crankcase with a banjo bolt and two new aluminum seals.
    3. 42.3. Secure both oil lines on the pump housing with a Torx screw (M6 x 12). → Tightening torque: 10 Nm (7.5 ft. lb.) 
    4. 42.4. Tighten M16 banjo bolt. → Tightening torque: 30 Nm (22 ft. lb.) 
43. Fit oil line for turbocharger oil tank with a new O-ring to the suction pump for the engine on side 1-3. Grease O-ring.
    1. 43.1. Secure oil line with a Torx screw (M6 x 12). → Tightening torque: 10 Nm (7.5 ft. lb.) 
44. Route and secure oil return line from engine to oil tank on the engine. Secure a rubberized clamp with a Torx screw (M6 x 12). → Tightening torque: 10 Nm (7.5 ft. lb.) 
45. Secure line to the oil suction pumps at the cylinder head. Tighten union nut (a/f 27) and counter at the screw socket with an open-ended wrench (a/f 24). → Tightening torque: 40 Nm (30 ft. lb.) 
46. Fit heat shields for ignition coils using two Torx screws (M6 x 12) on each. → Tightening torque: 10 Nm (7.5 ft. lb.)  .
47. Fit turbocharger. Fit new O-rings on all connecting lines and coat these with Kluber grease. Secure threaded connections for lines on turbocharger with stainless-steel screws.
48. Secure lines for turbocharger oil tank with Torx screws (M6 x 12). → Tightening torque: 10 Nm (7.5 ft. lb.)  .
49. Secure turbocharger to three-hole flange. Use new lock nuts. → Tightening torque: 28 Nm (21 ft. lb.)  .
50. Secure turbocharger holder to cylinder head using M8 Torx screws. → Tightening torque: 23 Nm (17 ft. lb.)  .
51. Screw turbocharger to holder with a Torx screw (M8 x 16). → Tightening torque: 23 Nm (17 ft. lb.)  .
52. Clip exhaust temperature sensor line into oil line holder. Fit sensor in turbocharger with a union nut. → Tightening torque: 35 Nm (26 ft. lb.) 
53. Fix oil supply lines for the turbocharger in place on side 4-6 on the holder, on side 1-3 on the camshaft housing cover with a rubberized clamp and one Torx screw (M6 x 12) on each line. → Tightening torque: 10 Nm (7.5 ft. lb.)  .
54. Fit coolant connection piece on the underside of the engine with aluminum sleeves and two Torx screws (M6 x 20) on each. Replace O-rings and coat new rings with Kluber grease. → Tightening torque: 10 Nm (7.5 ft. lb.)  .
55. Fit oil return line from crankcase to heat exchanger. Tighten two M6 x 16 Torx screws with a new metal seal at the top. Tighten the union nut (a/f 32) on the crankcase and counter with an open-ended wrench (a/f 32) while doing this. → Tightening torque: 10 Nm (7.5 ft. lb.)  ; → Tightening torque: 30 Nm (22 ft. lb.) 
56. Install drive belt → 137819 REMOVING AND INSTALLING DRIVE BELT .
57. Fit engine strut with rear silencer holder.
    1. 57.1. Unscrew screw (M10 x 60) used to secure the coolant guide module (see Step  23.2).
    2. 57.2. Screw in four Torx screws (M10 x 60) uniformly and tighten them. → Tightening torque: 65 Nm (48 ft. lb.) 
58. Place new O-rings on two combination valves for secondary air and fit the valves. Connecting flanges must be facing the flywheel side.
    1. 58.1. Coat O-rings with Kluber grease.
    2. 58.2. Fit two hexagon socket head bolts (M6 x 20) with a captive washer on each and tighten them. → Tightening torque: 10 Nm (7.5 ft. lb.) 
59. Secure coolant vent line on the heat exchangers with screw-type clamps and clip into the reservoir on intake distributor 1-3.
    Fig 13: Identifying Air Conditioning Compressor Cable Plug

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60. Clip fuel connecting line in on the heat exchanger and then fit the intake manifold. Fit new molded seals.
61. Connect electric change-over valve for turbocharger. Secure lines to intake pipe distributor with a screw-type clamp and connect them to the vacuum line for the tandem pump.
62. Route secondary air line and connect it to the combination valves.
63. Fit and tighten 12 hexagon socket head bolts (M6 x 25) for the intake manifold.
64. Fit fuel return line on side 4-6. Tighten union nut (a/f 19) and counter at the same time with an open-ended wrench (a/f 22). → Tightening torque: 30 Nm (22 ft. lb.) 
65. Fit M6 collar nut for throttle body holder and connect cable plug for electronic accelerator. → Tightening torque: 10 Nm (7.5 ft. lb.)  .
66. Connect all cable plugs for the engine wire harness → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .
67. Secure ground cable on side 1-3 and 4-6 to the cover of the camshaft housing with an M6 Torx screw. → Tightening torque: 10 Nm (7.5 ft. lb.)  .
68. Fit secondary air pump. Fit two Torx screws (M6 x 50) with a washer and tighten them. Fit two lines and cable plugs. → Tightening torque: 10 Nm (7.5 ft. lb.)  .
69. Grease new O-ring and fit O-ring on intake air lines on side 1-3 and 4-6, then fix in place in the holder with retaining rubber. Insert and tighten two Torx screws (M6 x 20) on the turbocharger flange. Route vacuum line and slide onto the turbocharger. → Tightening torque: 10 Nm (7.5 ft. lb.) 
70. Install oil tank. Position and tighten three M8 fastening screws. → Tightening torque: 23 Nm (17 ft. lb.) 
71. Grease new O-ring and fit O-ring on intake air line on side 4-6, then fix in place in the holder with retaining rubber. Insert and tighten two Torx screws (M6 x 20) on the turbocharger flange. Route vacuum line and slide onto the turbocharger. → Tightening torque: 10 Nm (7.5 ft. lb.) 
    Fig 14: Locating Intake Air Line And Electronic Adjuster Connector

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72. Position union nut for oil return line on the fuel tank and tighten it. Counter at the oil tank while doing this.→ Tightening torque: 60 Nm (44 ft. lb.) 
73. Install rear silencer with catalytic converter. Replace flange gaskets and M8 lock nuts. Fit a heat shield on both the left and right. Fit nuts with washers uniformly and tighten to the specified torque. → Tightening torque: 25 Nm (19 ft. lb.)  .
74. Secure clamps. → Tightening torque: 23 Nm (17 ft. lb.)  .