Special Features And Component Deviations - V6

WARNING: This page is about a different variant/trim than selected.

Information

Please note the following for the V6 =>

The repair concepts for the V6 are the same as for the V8.
The special features and component deviations are listed and shown in
> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS
More significant deviations are shown in separate descriptions.
If no special features are specifically highlighted, the assembly and adjustment instructions for the V8 apply.

Fig 1: Upper Part Of Crankcase Components Location With Torque Specification

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Upper part of crankcase

1	Upper part of crankcase
2	Cover
3	Sealing ring
4	Screw plug for upper cart of crankcase > Tightening torque 30 Nm (22 ftlb.) and > Torque angle 60°
5	Dowel sleeve
6	Oil spray jet
7	Screw. M6 x 16 > Tightening torque 10 Nm (7.5 ftlb.)

Fig 2: Lower Part Of Crankcase Components Location With Torque Specification (4WD)

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Lower part of crankcase, 4WD

1	Lower part of crankcase
2	Straight pin, 6 x 18
3	Dowel sleeve
4	Seal
5	Joint flange
6	Screw, M6 x 20 > Tightening torque 13 Nm (9.5 ftlb.)
7	Screw, M8 x 35 > Tightening torque 23 Nm (17 ftlb.)
8	Screw, M8 x 50 > Tightening torque 23 Nm (17 ftlb.)
9	Sealing rings for joint flange/cross tube
10	Cross tube for all-wheel drive cross shaft
11	Aluminium screw , M8 x 70; (cross bolt connection); always use new aluminium screws; > Initial tightening 10 Nm (7.5 ftlb.) and > Final tightening 90°
12	Thrust-bearing screw. M10; tighten screws within 5 minutes; observe specified tightening sequence! > Initial tightening 22 Nm (16 ftlb.) > Torque angle 60° Information The main bearing screws (4WD) for the fourth main bearing (feeding through all-wheel cross tube) are shorter than those for the 2WD engine. Do not confuse main bearing screws!
13	Thrust-bearing screw, M11; tighten screws within 5 minutes; observe specified tightening sequence! > Initial tightening 30 Nm (22 ftlb.) > Torque angle 90° Information The main bearing screws (4WD) for the fourth main bearing (feeding through all-wheel cross tube) are shorter than those for the 2WD engine. Do not confuse main bearing screws!
14	Sealing ring
-	Sealant application - Doboseal 224N (999.915.573.43, status 09/08)

Fig 3: Lower Part Of Crankcase Components Location With Torque Specification (2WD)

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Lower part of crankcase, 2WD

1	Lower part of crankcase
2	Straight pin, 6 x 18
3	Sealing ring
4	Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
5	Thrust-bearing screw. M11; tighten screws within 5 minutes; observe specified tightening sequence! > Initial tightening 30 Nm (22 ftlb.) > Torque angle 90° Information The main bearing screws (4WD) for the fourth main bearing (feeding through all-wheel cross tube) are shorter than those for the 2WD engine. Do not confuse main bearing screws!
6	Thrust-bearing screw. M10; tighten screws within 5 minutes; observe specified tightening sequence! > Initial tightening 22 Nm (16 ftlb.) > Torque angle 60° Information The main bearing screws (4WD) for the fourth main bearing (feeding through all-wheel cross tube) are shorter than those for the 2WD engine. Do not confuse main bearing screws!
7	Aluminium screw, M8 x 70; (cross bolt connection); always use new aluminium screws; > Initial tightening 10 Nm (7.5 ftlb.) and > Final tightening 90°
8	Screw, M8 x 35 > Tightening torque 23 Nm (17 ftlb.)
9	Screw. M8 x 50 > Tightening torque 23 Nm (17 ftlb.)
10	Dowel sleeve

Fig 4: Crankcase Screws Tightening Sequence

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Tightening sequence for crankcase

1 to 16	Tightening sequence for M11 and M10 screws => Observe different torques!
	Tightening sequence for securing lower part of crankcase to upper part of crankcase (M8 cross bolt connection) - start at the centre and tighten uniformly in diagonally opposite sequence

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Applying sealant to lower part of crankcase

1	Apply Doboseal 224N sealant (999.915.573.43, status 09/08); wipe off sealant residue following fitting

Fig 5: Bracket Components Location With Torque Specification (2WD)

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Bracket, 2WD

1	Bracket for auxiliary units
2	Screw, M10 x 45 > Tightening torque 65 Nm (48 ftlb.)
3	Dowel sleeve
4	Hydraulic mount, left
5	Nut, M12 > Tightening torque 120 Nm (89 ftlb.)

Fig 6: Bracket Components Location With Torque Specification (4WD)

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Bracket, 4WD

1	Bracket for auxiliary units
2	Screw, M10 x 45 > Tightening torque 65 Nm (48 ftlb.)
3	Dowel sleeve
4	Hydraulic mount, left
5	Nut, M12 > Tightening torque 120 Nm (89 ftlb.)

Fig 7: Engine Mount Bracket Components Location With Torque Specification

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Bracket for engine mount

1	Engine carrier
2	Screw. M10x 45 > Tightening torque 65 Nm (48 ftlb.)
3	Nut, M12 x 1.5 > Tightening torque 120 Nm (89 ftlb.)
4	Hydraulic mount, right

Fig 8: Oil Mist Separator Components Location

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Oil mist separator

1	Engine ventilation/oil mist separator
2	Moulded seal
3	Moulded seal
-	Screw elements, M6 (permanently secured in oil mist separator) > Tightening torque 10 Nm (7.5 ftlb.)

Fig 9: Ventilation Components Location

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Ventilation

1	Engine ventilation line
2	Line for oil mist separator to intake-air distributor
3	Aluminium holder
4	Tank ventilation
5	Aluminium screw (holder); see Timing-case cover

Fig 10: Crankshaft Mount Sealing Ring Components Location

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Crankshaft mount sealing ring

1	Crankshaft
2	Straight pin, 6 x 20
3	Spring, 5 x 6.5
4	Thrust washer (grooves facing out)
5	Main bearing shell, upper
6	Main bearing shell, lower
7	Shaft sealing ring => Do not touch sealing ring lip! Clean crankshaft flange and oil lightly
-	Crankshaft bearing classification (four types) G Yellow; B Blue, R Red; N Green => (example: GGGG-BBB; 4 main shaft bearings with yellow marking, 3 double (6) connecting rod bearings with blue marking) => For numbering, see flywheel flange
-	Direction of travel (main bearing 1 is the first in direction of travel against output)

Fig 11: Auxiliary Units Components Location With Torque Specification

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Auxiliary units

1	Air-conditioning compressor
2	Screw, M10 x 100 > Tightening torque 46 Nm (34 ftlb.)
3	Screw, M8 x 100 > Tightening torque 23 Nm (17 ftlb.)
4	Screw, M8 x 20; tandem pump to bracket for auxiliary units > Tightening torque 23 Nm (17 ftlb.) ; power-steering pump to bracket for auxiliary units > Tightening torque 23 Nm (17 ftlb.)
5	Tandem pump
6	Screw, M8 x 35; power-steering pump to adapter bracket > Tightening torque 23 (1 7 ftlb.) Nm ; tandem pump/adapter bracket to bracket for auxiliary units > Tightening torque 23 Nm (17 ftlb.)
7	Power-steering pump
8	Aluminium screw , M8; always use new aluminium screws > Initial tightening 10 Nm (7.5 ftlb.) and > Final tightening 90°
9	Support bracket made of magnesium
10	Dowel sleeve

Fig 12: Vibration Balancer Pulleys Components Location With Torque Specification

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Vibration balancer pulleys

1	Water pump pulley
2	Screw, M8 x 16 > Tightening torque 23 Nm (17 ftlb.)
3	Vibration damper
4	Screw, M18 x 1.5 x 72; use new screw; > Tightening torque 20 Nm (15 ftlb.) and > Tightening torque 50 Nm (37 ftlb.) and > Tightening torque 100 Nm (74 ftlb.) and > Torque angle 180°
5	Power-steering pump pulley
6	Screw, M8 x 16 > Tightening torque 23 Nm (17 ftlb.)
7	Tandem pump pulley

Fig 13: Belt Drive Components Location With Torque Specification

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Belt drive

1	Deflection roller > Tightening torque 32 Nm (24 ftlb.)
2	Hydraulic belt tensioner; tensioner to lever > Tightening torque 32 Nm (24 ftlb.) ; tensioning roller to tensioning lever > Tightening torque 32 Nm (24 ftlb.)
3	Screw, M8 x 96; complete lever to timing-case cover and cylinder head > Tightening torque 32 Nm (24 ftlb.) ; belt tensioner and timing-case cover to bracket > Tightening torque 32 Nm (24 ftlb.)
4	Deflection roller > Tightening torque 32 Nm (24 ftlb.)
5	Dual poly V-belt

Fig 14: Timing-Case Cover - Chain Tensioner Sealing Flange Components Location With Torque Specification

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Timing-case cover - chain tensioner sealing flange

1	Joint flange foil sealing lip with engine oil); align with sleeve or vibration balancer/replace
2	Aluminium screw , M6 x 55; always use new aluminium screws; > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°
3	Aluminium screw M6 x 20; always use new aluminium screws; > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°
4	Chain tensioner (Do not confuse V6 chain tensioner with V8 chain tensioner , colour of V6 chain tensioner is different to the V8 chain tensioner) > Tightening torque 60 Nm (44 ftlb.) and sealing ring; always replace sealing ring

Fig 15: Cylinder Head Components Location With Torque Specification

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Cylinder head 1 to 3

-	Cylinder head 1 to 3
1	Spark plug; when re-installed > Tightening torque 25 Nm (19 ftlb.) ; if fitting new spark plugs > Tightening torque 30 Nm (22 ftlb.) Electrode gap of spark plug FGR5NQE > Control value 1.6 mm +/- 0.05 mm Electrode gap of spark plug FR6NPP > Control value 0.7 mm + 0.1 mm
2	Cylinder-head gasket 1 to 3
3	Screw, M8 > Tightening torque 23 Nm (17 ftlb.)
4	Cover
5	Stopper
6	Stopper
7	Restrictor for valve lift adjustment > Tightening torque 2 Nm (1.5 ftlb.)
8	Cylinder head screws => For tightening specifications, see Tightening sequence for cylinder head

Fig 16: Cylinder Head Components Location With Torque Specification

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Cylinder head 4 to 6

1	Cylinder head 4 to 6
2	Screw plug > Tightening torque 5 Nm (3.5 ftlb.)
3	Spark plug; when re-installed > Tightening torque 25 Nm (19 ftlb.) ; if fitting new spark plugs > Tightening torque 30 Nm (22 ftlb.) Electrode gap of spark plug FGR5NQE > Control value 1.6 mm +/- 0.05 mm Electrode gap of spark plug FR6NPP > Control value 0.7 mm + 0.1 mm
4	Cylinder-head gasket 4 to 6
5	Stopper
6	Restrictor for valve lift adjustment > Tightening torque 2 Nm (1.5 ftlb.)
7	Stopper
8	Cover
9	Cylinder head screws => For tightening specifications, see Tightening sequence for cylinder head

Fig 17: Cylinder Head Screws Tightening Sequence

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Tightening sequence for cylinder head

1 to 8

1st initial tightening > Tightening torque 30 Nm (22 ftlb.) ; 2nd initial tightening > Tightening torque 50 Nm (37 ftlb.) ; loosen by 2 turns > Torque angle 720° ; 1st turn > Tightening torque 30 Nm (22 ftlb.) ; 2nd turn > Tightening torque 30 Nm (22 ftlb.) ; 3rd turn and final tightening (torque angle) > Torque angle 110°

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Marking on camshaft housing, cylinders 1 to 3

All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads
1	Matching number for cylinder head/intake camshaft housing, cylinder 1 [E1]
2	Matching number for cylinder head/intake camshaft housing, cylinder 2 [E2]
3	Matching number for cylinder head/intake camshaft housing, cylinder 3 [E3]
4	Matching number for cylinder head/outlet camshaft housing, cylinder 1 [A1]
5	Matching number for cylinder head/outlet camshaft housing, cylinder 2 [A2]
6	Matching number for cylinder head/outlet camshaft housing, cylinder 3 [A3]
arrow	Direction of travel

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Marking camshafts

1-3	Cylinders 1 to 3
4-6	Cylinders 4 to 6
-	Outlet camshaft identification [green]
-	Intake camshaft identification [white]
arrow	Direction of travel

Fig 18: Cylinder Head Camshafts, Cylinders 1 To 3 Components Location With Torque Specification

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Cylinder head camshafts, cylinders 1 to 3

1	Camshaft (outlet)
2	Camshaft (intake)
3	Hydraulic valve for variable valve lift control
4	Screw, M5 x 12 > Tightening torque 6 Nm (4.5 ftlb.)
5	Switching tappet (oil with engine oil)
6	Bucket tappet (oil with engine oil)
8	Mounting saddle 1 to 3
9	Stopper
-	Bearing locations (oil with engine oil)

Fig 19: Camshaft Mount, Cylinder Bank 1 To 3 Components Location With Torque Specification

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Camshaft mount, cylinder bank 1 to 3

1	Screw, M6 x 35 > Tightening torque 13 Nm (9.5 ftlb.)
2	Bearing cover
3	Dowel sleeve
4	Bearing cover (intake)
5	Bearing cover (outlet)
6	Screw, M6 x 70 > Tightening torque 13 Nm (9.5 ftlb.)
-	Bearing surfaces (oil with engine oil)

Fig 20: Cylinder Head Camshafts, Cylinders 4 To 6 Components Location With Torque Specification

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Cylinder head camshafts, cylinders 4 to 6

1	Switching tappet [oil with engine oil]
2	Bucket tappet (oil with engine oil)
3	Camshaft (intake)
4	Driver for drive coupling for high-pressure pump
5	Fuse (not functionally relevant if not installed)
6	Hydraulic valve for variable valve lift control
7	Screw, M5 x 12 > Tightening torque 6 Nm (4.5 ftlb.)
8	Camshaft (outlet)
9	Stopper
10	Mounting saddle, cylinders 4 to 6
11	Stopper

Fig 21: Camshaft Mount, Cylinder Bank 4 To 6 Components Location With Torque Specification

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Camshaft mount, cylinder bank 4 to 6

1	Dowel sleeves
2	Bearing cover (intake)
3	Screw, M6 x 70 > Tightening torque 13 Nm (9.5 ftlb.)
4	Bearing cover
5	Screw, M6 x 35 > Tightening torque 13 Nm (9.5 ftlb.)
6	Bearing cover (outlet)
-	Bearing surfaces (oil with engine oil)

Fig 22: Guide Rail And Tensioning Rail Components Location With Torque Specification

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Guide rail and tensioning rail

1	Threaded peg > Tightening torque 35 Nm (26 ftlb.)
2	Threaded peg > Tightening torque 20 Nm (15 ftlb.)
3	Guide rail
4	Tensioning rail
5	Chain tensioner with sealing ring; always replace sealing ring; do not confuse V6 chain tensioner with V8 chain tensioner , colour of V6 chain tensioner is different to the V8 chain tensioner > Tightening torque 60 Nm (44 ftlb.)
arrow	Direction of travel

Fig 23: Valve Cover Seals, Fitted On Cylinder Bank 1 To 3 Components Location With Torque Specification

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Valve cover seals, fitted on cylinder bank 1 to 3

1	Aluminium Screw , M6 x 20; hall sender (phase sensor); always use new aluminium screws > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°
2	Hall sender
3	Sealing ring
4	Cylinder-head cover gasket
5	Cylinder-head cover gasket, inner
6	Seal for hydraulic valve for camshaft control
7	Valve cover for cylinders 1 to 4 (align over bar ignition modules)
8	Oil cap

Fig 24: Valve Cover Seals, Fitted On Cylinder Bank 4 To 6 Components Location With Torque Specification

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Valve cover seals, fitted on cylinder bank 4 to 6

1	Valve cover for cylinders 4 to 6 (align over bar ignition modules)
2	Hall sender
3	Aluminium Screw, M6 x 20; hall sender (phase sensor); always use new aluminium screws > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°
4	Sealing ring
5	Cylinder-head cover gasket
6	Cylinder-head cover gasket, inner
7	Seal for hydraulic valve for camshaft control

Fig 25: Valve Cover, Mounting For Cylinder Bank 1 To 3 Components Location With Torque Specification

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Valve cover, mounting for cylinder bank 1 to 3

1	Bar ignition module
2	Valve cover for cylinder bank 1 to 3 (align over bar ignition modules)
3	Aluminium Screw, M6 x 30; always use new aluminium screws; > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°
4	Cap
5	Steel screw to eyelet > Tightening torque 23 Nm (17 ftlb.)
6	Eyelet
7	Aluminium screw , M8 x 35 (on torque support); always use new aluminium screws; > Initial tightening 10 Nm (7.5 ftlb.) and > Final tightening 90° Steel screw to eyelet. Information The eyelets must not be inadvertently secured using aluminium screws! => Aluminium screws would break off and the suspended engine would fall down!
8	Aluminium screw, M6 x 20; bar ignition module; always use new aluminium screws; > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°

Fig 26: Valve Cover, Mounting For Cylinder Bank 4 To 6 Components Location With Torque Specification

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Valve cover, mounting for cylinder bank 4 to 6

1	Valve cover for cylinder bank 4 to 6 (align over bar ignition modules)
2	Eyelet
3	Steel screw to evelet > Tightening torque 23 Nm (17 ftlb.) Information The eyelets must not be inadvertently secured using aluminium screws! => Aluminium screws would break off and the suspended engine would fall down!
4	Aluminium screw , M6 x 30; always use new aluminium screws; > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°
5	Bar ignition module
6	Aluminium screw. M6 x 20; bar ignition module; always use new aluminium screws; > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°
7	Sheetmetal holder
8	Cap

Fig 27: Cylinder Head Cover, Cylinder Bank 1 To 3 Screws Tightening Sequence

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Tightening sequence for cylinder head cover, cylinder bank 1 to 3

Fig 28: Cylinder Head Cover, Cylinder Bank 4 To 6 Screws Tightening Sequence

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Tightening sequence for cylinder head cover, cylinder bank 4 to 6

Fig 29: Oil Pump Chain Drive On Chain Pinion Components Location

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Oil pump chain drive on chain pinion

1	Crankshaft sprocket
2	Friction plates/diamond washers; can be re-used
3	Drive chain for oil pump balance shaft module
4	Screw securing timing chain (screw into crankcase)
-	Guide and tensioning rail module
-	Fastening screws (for tightening specifications, see oil pump)
-	Spring wedge for crankshaft

Fig 30: Oil Pump Chain Guide Components Location With Torque Specification

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Oil pump chain guide

1	Drive chain for oil pump balance shaft module
2	Guide and tensioning rail module
3	Fastening screw, M6 x 35 > Tightening torque 13 Nm (9.5 ftlb.)
4	Fastening screws, M6 x 20 > Tightening torque 13 Nm (9.5 ftlb.)

Fig 31: Oil Pump With Balance Shaft Components Location With Torque Specification

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Oil pump with balance shaft

1	Oil pump with balance shaft
2	Dowel sleeve
3	Screw, M8 x 50 (4 ea.); 1st turn > Initial tightening 10 Nm (7.5 ftlb.) ; final tightening (torque angle) > Torque angle 80°
4	Screw, M8 x 70 (1 ea.); 1st turn > Initial tightening 10 Nm (7.5 ftlb.) ; final tightening (torque angle) > Torque angle 110°
5	Screw, M8 x 100 (1 ea.); 1st turn > Initial tightening 10 Nm (7.5 ftlb.) ; final tightening (torque angle) > Torque angle 120°
6	Screw, M10 x 45; replace; 1st turn > Initial tightening 20 Nm (15 ftlb.) ; final tightening (torque anale) > Torque angle 30°
7	Drive chain
8	Screw, M8 x 22; replace; 1st turn > Initial tightening 20 Nm (15 ftlb.) ; final tightening (torque anale) > Torque angle 90°
9	Oil pump sprocket
10	Solenoid valve
11	Sealing rings (grease before fitting)
12	Cap screw, M36 > Tightening torque 40 Nm (30 ftlb.)

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Tightening specifications for oil pump and staking position of balance shaft with respect to oil pump

arrow A	View A; top view of balance weight on balance shaft; staking position using 6-mm drill bit or staking pin
SW 36	36 mm across flats (a/f); counter with an open-ended wrench

Fig 32: Oil Pipes, Fitted On Oil Pump And Oil Guide Housing Components Location With Torque Specification

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Oil pipes, fitted on oil pump and oil guide housing

1	Oil pressure pipe
2	Sealing ring; oil before fitting
3	Sealing ring; oil before fitting
4	Oil regulating line
5	Sealing ring; oil before fitting
6	Sealing ring; oil before fitting
7	Intake pipe on oil pump
8	Oil pipes to oil pump and oil guide housing > Tightening torque 12 Nm (9 ftlb.)
9	Oil pipes to oil pump and oil guide housing > Tightening torque 12 Nm (9 ftlb.)
10	Sprocket cover
11	Fastening screws on sprocket cover > Tightening torque 12 Nm (9 ftlb.)

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Oil pipes, fitted on oil pump and oil guide housing (view without oil pan)

Fig 33: Oil Pressure Sensor Components Location With Torque Specification

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Oil pressure sensor

1	Stopper > Tightening torque 15 Nm (11 ftlb.)
2	Sealing ring
3	Oil-pressure sensor adapter
4	Sealing ring
5	Oil pressure sender with temperature sensor
6	Screw, M6 x 40 > Tightening torque 10 Nm (7.5 ftlb.)

Fig 34: Oil Guide Housing For Oil Filter Heat Exchanger Components Location With Torque Specification (2WD)

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Oil guide housing for oil filter heat exchanger, 2WD

1	Oil guide housing
2	Oil/water heat exchanger
3	Screw, M6 x 20; self-tapping screws ex-works; metric screws can also be used > Tightening torque 10 Nm (7.5 ftlb.)
4	Heat exchanger seal
5	Heat exchanger clip
6	Oil-filter cover > Tightening torque 25 Nm (19 ftlb.)
7	Oil filter
8	Oil-filter gasket
9	Oil duct adapter (cannot be replaced)

Fig 35: Oil Guide Housing For Oil Filter Heat Exchanger Components Location With Torque Specification (4WD)

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Oil guide housing for oil filter heat exchanger, 4WD

1	Oil guide housing
2	Oil/water heat exchanger
3	Screw, M6 x 20; self-tapping screws ex-works; metric screws can also be used > Tightening torque 10 Nm (7.5 ftlb.)
4	Heat exchanger seal
5	Heat exchanger clip
6	Oil-filter cover > Tightening torque 25 Nm (19 ftlb.)
7	Oil filter
8	Oil-filter gasket
9	Oil duct adapter (cannot be replaced)

Fig 36: Oil Return Oil Plate Components Location With Torque Specification (2WD)

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Oil return oil plate, 2WD

1	Oil guide (oil plate)
2	Oil return seal
3	Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.)

Fig 37: Oil Return Oil Plate Components Location With Torque Specification (4WD)

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Oil return oil plate, 4WD

1	Oil guide (oil plate)
2	Oil return seal
3	Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.)

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Applying seal on oil guide housing, 2WD

1	Sealant application (geometry, sealing bead 1 mm); Doboseal 224N (999.915.573.43, status 01/10)

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Applying seal on oil guide housing, 4WD

1	Sealant application (geometry, sealing bead 1 mm); Doboseal 224N (999.915.573.43, status 01/10)

Fig 38: Oil Pan Components Location With Torque Specification

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Oil pan

1	Oil pan
2	Seal; replace following removal
3	Seal; replace following removal
4	Oil drain plug, M18; aluminium screw; can be reused > Tightening torque 30 Nm (22 ftlb.)
5	Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.)

Fig 39: Water Guide For Heating Pipe/Collection Pipe Components Location With Torque Specification

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Water guide for heating pipe/collection pipe

1	Coolant pipe for heater
2	Screw plug > Tightening torque 15 Nm (11 ftlb.)
3	Sealing ring
4	Screw, M6 > Tightening torque 12 Nm (9 ftlb.)
5	Sealing ring
6	Screw plug > Tightening torque 30 Nm (22 ftlb.)
7	Screw > Tightening torque 12 Nm (9 ftlb.)
8	Coolant guide tube (collection pipe)
9	Metal seal
10	Stoppers

Fig 40: Cooling Water Return Hose Ahead Of Belt Drive Components Location With Torque Specification

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Cooling water return hose ahead of belt drive

1	Connection piece on generator
2	Screw for connection piece > Tightening torque 10 Nm (7.5 ftlb.)
3	Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.)
4	Coolant return line
5	Coolant return hose assembly
6	Holder
7	Screw, M6 Aluminium screw ; always use new aluminium screws > Initial tightening 4 Nm (3 ftlb.) and > Final tightening 90°

Fig 41: Cooling Water Supply Hose Components Location With Torque Specification

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Cooling water supply hose

1	Coolant supply hose for oil/coolant heat exchanger
2	Screw for connection piece > Tightening torque 10 Nm (7.5 ftlb.)
3	Coolant supply hose to generator
4	Connection piece on generator
5	Coolant pipe
6	Screw, M6; coolant line to collection pipe > Tightening torque 10 Nm (7.5 ftlb.)

Fig 42: Ventilation Components Location With Torque Specification

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Ventilation

1	Screw, M6 x 16 > Tightening torque 10 Nm (7.5 ftlb.)
2	Vent line

Fig 43: Intake-Air Distributor - V6 Components Location With Torque Specification

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Intake-air distributor - V6

1	Intake module
2	Decoupling module (fastening part); observe tightening sequence > Tightening torque 10 Nm (7.5 ftlb.)
3	Intake module seal; check that seal is aligned and fitted correctly!
4	Heat socket
5	Screw, 5 x 16 > Tightening torque 2 Nm (1.5 ftlb.)
6	Screw, 6 x 45 > Tightening torque 7 Nm (5 ftlb.)
7	Electronic accelerator
8	Seal
9	Ball socket

Fig 44: Pressure Sensor Shift Mechanism Components Location With Torque Specification

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Pressure sensor shift mechanism

1	Pressure sensor
2	Screw > Tightening torque 7 Nm (5 ftlb.)
3 to 10	Actuators
7	Vacuum line
8	Screw, M5 x 16 > Tightening torque 4 Nm (3 ftlb.)

Fig 45: Intake-Air Distributor Screws Tightening Sequence

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Intake-air distributor tightening sequence

Fig 46: Fuel Distributor Pipe Components Location With Torque Specification

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fuel distributor pipe

1	Fuel distributor pipe (fuel gallery)
2	Stopper; in 3 turns (tighten, loosen, tighten) > Tightening torque 25 Nm (19 ftlb.)
3	High-pressure sensor > Tightening torque 20 Nm (15 ftlb.)

Fig 47: Fuel Injectors Components Location With Torque Specification

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Fuel injectors

1	Twin holder (retainer for two injectors) => for cylinders 2 to 3 and 4 to 5
2	Screw, M8 x 30 > Tightening torque 23 Nm (17 ftlb.)
3	Single holder (retainer for one injector) => for cylinders 1 and 6
4	Injector (high-pressure fuel injector)

Fig 48: Fuel Distributor Pipe 2 Components Location With Torque Specification

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Fuel distributor pipe 2

1	Screw, M6 x 16 > Tightening torque 10 Nm (7.5 ftlb.)
2	Screw, M6 x 25 > Tightening torque 10 Nm (7.5 ftlb.)
-	Connection to injector (high-pressure fuel injector); in 3 turns (tighten, loosen, tighten) > Tightening torque 25 Nm (19 ftlb.)

Fig 49: High-Pressure Pump Components Location With Torque Specification

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High-pressure pump

1	High-pressure pump
2	High-pressure line; (3 turns: tighten, loosen, tighten) > Tightening torque 25 Nm (19 ftlb.)
3	Low-pressure line; M6 screw > Tightening torque 10 Nm (7.5 ftlb.) and connection to high-pressure pump for low-pressure line; (3 turns: tighten, loosen, tighten); counter at hexagon on high-pressure pump > Tightening torque 25 Nm (19 ftlb.)
4	Screw socket, M8 > Tightening torque 23 Nm (17 ftlb.)
5	Screw socket. M6 > Tightening torque 10 Nm (7.5 ftlb.)
6	Protective plate
7	Screw, M6 x 20 > Tightening torque 10 Nm (7.5 ftlb.)
-	Required line distance (5 to 8 mm) between components

Fig 50: Vacuum Pump Components Location With Torque Specification

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Vacuum pump

1	Vacuum pump
2	Screw, M6 x 25 > Tightening torque 10 Nm (7.5 ftlb.)
3	Sealing ring
4	Sealing ring

Fig 51: Exhaust Manifold Seal, Cylinders 1 To 3 Components Location With Torque Specification

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Exhaust manifold seal, cylinders 1 to 3

1	Exhaust manifold
2	Studs, M8;
3	Hexagon nut. M8; replace; (check nuts by clicking once); observe correct tightening sequence > Tightening torque 27 (20 ftlb.) (check nuts by clicking once) Nm
-	Exhaust manifold seal
-	M6 screw; heat shield to exhaust manifold; > Tightening torque 10 Nm (7.5 ftlb.)

Fig 52: Exhaust Manifold Seal, Cylinders 4 To 6 Components Location With Torque Specification

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Exhaust manifold seal, cylinders 4 to 6

1	Exhaust manifold
2	Seal
3	Hexagon nut, M8; replace; (check nuts by clicking once); observe correct tightening sequence > Tightening torque 27 (20 ftlb.) (check nuts by clicking once) Nm
4	M6 screw; heat shield to exhaust manifold; > Tightening torque 10 Nm (7.5 ftlb.)

Fig 53: Exhaust Manifold Screws Tightening Sequence

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Exhaust manifold tightening sequence, cylinders 1 to 3

Fig 54: Exhaust Manifold Screws Tightening Sequence

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Exhaust manifold tightening sequence, cylinders 4 to 6