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.

→ Wear personal protective gear.

→ Get someone to help if necessary.

→ Components must have reached at least 17°C throughout.

→ Components must not be too hot (distortion).

→ Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.

→ Place a drip tray under the engine at the assembly support.

→ Have a sufficient number of cleaning cloths ready.

→ Close off engine openings with plugs.

Information 

The tightening specifications for the basic engine are stored centrally (→ 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS ).

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information 

• The bearing shells are available in various classes. The classes are indicated by the color marking on the outside. For every bearing (main and connecting rod bearings), the color marking must match the corresponding letter on the flywheel flange of the crankshaft  . -arrow- Each letter on the flywheel flange of the crankshaft indicates the correct color classification of the bearing shell  .
  Fig 1: Locating Bearing Shell Color Marking

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Information 

• The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod  .
• When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank  .
• The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings  .
• The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- . The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank  .
• When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank  .
• Naturally aspirated engines and turbo engines have different pistons  .
  Fig 2: Identifying Connecting Rod Code

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• The code on the connecting-rod big end and connecting rod cap must always be on the same side and at the exhaust side  . -A- 
  NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
  Fig 3: Identifying Connecting Rod Code

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Information 

• Connecting rod bolts must always be replaced  .

1. Place crankshaft bearing shells into the lower part of the crankcase.
   1. 1.1. Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9-  . Example: GGGGB GGGG  mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The engraved letters are the abbreviations for the color code of the bearing shells (G  for yellow  , B  for blue  , R  for red  , N  for green  ). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells should all have a yellow marking in this case.
      1. Crankshaft (stroke: 83 mm)
      2. Straight pin, 6 x 20
      3. Spring wedge
      4. Thrust washer
      5. Main bearing shell, upper
      6. Main bearing shell, lower
      7. Shaft seal
      8. View of crankshaft flange
      9. Crankshaft bearing classification (four types) G  Yellow; ↑B  Blue, R  Red; N  Green => (example: GGGGG-BBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) => For numbering, see A 
      Fig 4: Identifying Crankshaft, Thrust Washer And Main Bearing Shell

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   2. 1.2. Place crankshaft bearing shells with lubricating groove and bore -2-  into the upper part of the crankcase -1-  . Smooth crankshaft bearing shells -3-  belong in the lower part of the crankcase. Insert the thrust washers into the center with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.
      Fig 5: Identifying Bearing Shells

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      Fig 6: Inserting Bearing Shells

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      Fig 7: Identifying Thrust Washer

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   3. 1.3. Oil crankshaft bearing shells on the outside and inside with engine oil and insert correctly into ↓the lower part of the crankcase according to the twist lock. Place lower part of crankcase on a clean surface. The retaining lugs (twist lock) prevent it from being installed incorrectly. As the thrust washers fall off without the crankshaft, do not insert until after the crankshaft is fitted.
2. If you have not already done so, fit knock sensors on the upper part of the crankcase using screws.
   1. 2.1. Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel to the cylinder head and the plug connection parallel to the starter. Fit knock sensors hand-tight.
   2. 2.2. Insert starter briefly and align concealed knock sensors so that there is no knock sensor near the starter. Remove the starter. Fit plug connection for knock sensor between cylinders 3 and 4 in the direction of the water pump so that it is turned upwards and slightly towards the cylinder head. Fit plug connection for knock sensor between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards and slightly towards the cylinder head.
   3. 2.3. Fit knock sensors correctly.
      1. Knock sensor
      2. Screw, M8 x 35
      Fig 8: Identifying Knock Sensors Screws
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   4. 2.4. Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2- 
      Fig 9: Identifying Crankcase And Thermostat Housing Seals

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3. Check coolant guide (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals on left and right, screw in screws securely on metal seals by hand. Move coolant guide at the upper part of the crankcase into installation position and fit it.
   1. Coolant pipe
   2. M6 screw
   3. Sealing ring
   4. Screw plug, M16 x 1.5
   5. M6 screw
   6. Coolant guide tube (collection pipe)
   7. Metal seal
   8. Stopper
   Fig 10: Identifying Coolant Guide, Sealing Ring, Metal Seal And Screws
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4. Fit oil spray jets -6-  .
   Fig 11: Identifying Crankcase Upper Part

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   Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease the sealing ring sparingly with Kluber Syntheso GLEP 1 and fit it. Check that oil spray jets are pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet must be aimed at the piston crown.

   → Spray direction → Spray direction from side 

   Fig 12: Identifying Oil Spray Jets

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   Fig 13: Identifying Oil Spray Jets (Side View)

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5. Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a plastic hammer if necessary.
6. Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. For details, see → 131037 DISASSEMBLING AND ASSEMBLING PISTONS
   1. Piston-ring set
   2. Pistons
   3. Circlip/piston-pin circlip
   4. Piston pins
   5. Connecting rods
   6. Connecting rod bolt; replace as it must be tightened in the plastic area
   7. Connecting-rod bearing shells
   Fig 14: Identifying Piston And Connecting Rod
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7. Check that all the seals are installed in the oil plate (oil return). → Oil return (oil plate) 
   Fig 15: Identifying Oil Return Line (Oil Plate)

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8. If you have not already done so, drive dowel sleeves for the metal seals in the timing-case cover using a copper or plastic hammer.
9. Insert new metal seals on the timing-case cover and press onto dowel sleeves.
10. Oil pump is pre-fitted with the oil pressure control valve.
11. Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings, which have been marked according to installation position, can be set down on a clean surface together with the corresponding camshafts. Cam followers and injectors are fitted.
12. If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power-steering pump or tandem pump using a copper or plastic hammer.
13. Move starter into installation position and screw down. → INSTALLING STARTER
14. Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
15. First position the timing chain pinion with the ring gear of the oil pump drive onto the crankshaft stub (check that the two diamond washers at the front and rear on the ring gear are clipped in -1-  ). Then position the drive pinion of the oil pump chain -2-  with respect to the crankcase.
    Fig 16: Pressing Timing Chain Pinion On Crankshaft Stub

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    Fig 17: Identifying Timing Chain Pinion (Diamond Washers)

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16. Fit crankshaft holding bridge holding bridge 9677/1  in the center of the crankshaft.
    Fig 18: Identifying Crankshaft Secured Bolt

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17. Turn upper part of crankcase and oil cylinder liners.
18. Pre-tension pistons using an assembly funnel funnel 9784/1  and press pistons into the cylinder. For details, see → 131020 REMOVING AND INSTALLING PISTONS
19. Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 04/10) to the lower part of the crankcase as shown. Insert sealing ring -3-  into the upper part of the crankcase and position the lower part of the crankcase onto the upper part of the crankcase. Insert all the fastening screws, fit to the prescribed tightening torque within 5 minutes and wipe off excess sealant.
    1. Wipe off sealant residues after fitting
    1. Direction of travel
    Fig 19: Applying Sealant

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20. Tighten M11 and M10 bearing screws to the prescribed torques. → Tightening sequence for thrust-bearing screws below 
    Fig 20: Thrust-Bearing Screws Tightening Sequence

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    1 bis 20  - Tightening sequence for M11 and M10 screws => Observe different torques!

    1. Direction of travel
    1. Lower part of crankcase
    2. Straight pin, 6 x 18
    3. O-ring
    4. Sealant application - Doboseal 224N (999.915.573.43, status 04/10)
    5. Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence.
    6. Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence.
    7. Aluminum screw  , M8 x 70; (cross bolt connection); always use new aluminum screws
    8. Screw, M8 x 35
    9. Screw, M8 x 50
    10. Dowel sleeve
    1. Direction of travel
    Fig 21: Identifying Crankcase Lower Part

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21. Fit cross bolt connection.
    Fig 22: Crankcase Bolts Tightening Sequence

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22. Fit M8 screws on the side -8 and 9-  . Remove emerging sealant.
23. Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm number embossing tool and counter at the cast-metal part with a hammer.
24. Move oil plate with all the seals into installation position and secure to the lower part of the crankcase.
    Fig 23: Identifying Oil Guide Screws (Oil Plate)

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25. Fit the oil pump → Oil pump on naturally aspirated engine  below.
    Fig 24: Identifying Oil Pump Components - Naturally Aspirated Engine

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26. Position the oil pump sprocket with drive chain with respect to the crankshaft chain pinion → Oil pump chain  below. Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw.
    Fig 25: Positioning Oil Pump Chain

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    Fig 26: Turning Oil Pump Pinion

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27. Fit cover plate for oil pump drive (drive pinion cover) using three screws.
28. Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both cylinder head seals. Part number/marking  facing upward. When doing so, make sure that the cylinder head gasket is positioned on the dowel sleeves.
29. Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not already done so), as the bores in the cylinder head screws are covered. -8- 
    1. Camshaft (outlet)
    2. Camshaft (intake)
    3. Hydraulic valve for variable valve lift control
    4. Screw, M5 x 12
    5. Switching tappet (oil with engine oil)
    6. Bucket tappet (oil with engine oil)
    7. Stopper
    8. Mounting saddle 1 to 4
    9. Stopper
    10. Bearing locations (oil with engine oil)
    1. Direction of travel
    Fig 27: Identifying Camshafts (Cylinder Bank 1 To 4)
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30. Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.
    1. Cylinder head 1 to 4
    2. Cylinder head gasket 1 to 4
    3. M8 screw
    4. Cap
    5. Stopper
    6. Stopper
    7. Restrictor for valve lift adjustment
    8. Cylinder-head screws => For tightening specifications, see Fig 29
    9. Spark plug
    Fig 28: Identifying Cylinder Head (1 To 4)
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31. Fit front M8 screw of cylinder head 1 to 4. -3- 
Fig 29: Cylinder Head Screws Tightening Sequence
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32. Coat camshaft bearings with normal multipurpose grease or engine oil.
33. Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet side have different diameters). The bucket tappets have a twist lock that fits into a guide groove in the cylinder head. Fit used bucket tappets at the same position.
34. Position vibration balancer with screw tightened by hand. Turn crankshaft to just before cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). -2- 
    Fig 30: Identifying Crankshaft Position Angle

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    Information 

    A data matrix coding is shown on the staking dihedron of the camshafts. This is a square black/white dotted marking used for electronic identification purposes during the production process. This marking can be used as an aid when inserting the camshafts into the cylinder head. All four camshafts press against the valves the least when the data matrix coding is facing upwards during installation.

35. Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and coat bearing locations with normal multipurpose grease or engine oil. Position bearing covers correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft bearing covers evenly and gradually, and slowly tighten to the specified tightening torque. The camshafts must not be strained or tilted. Outlet camshafts and intake camshafts (also bank-specific) cannot be used interchangeably because of the bearing locations and length.
    1. Cylinders 1 to 4
    2. Cylinders 5 to 8
    Fig 31: Camshaft Identification - V8 Naturally Aspirated Engine
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    1. Outlet camshaft identification (green)
    2. Intake camshaft identification (white)
    3. Intake camshaft identification (white)
    4. Outlet camshaft identification (green)
    • 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 bearing cover, cylinder 1 (E1)
    2. Matching number for cylinder head/intake camshaft bearing cover, cylinder 2 (E2)
    3. Matching number for cylinder head/intake camshaft bearing cover, cylinder 3 (E3)
    4. Matching number for cylinder head/intake camshaft bearing cover, cylinder 4 (E4)
    5. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1)
    6. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 2 (A2)
    7. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 3 (A3)
    8. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 4 (A4)

    Arrow  - Direction of travel

    Fig 32: Camshaft Bearing Cover Identification

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    1. Dowel sleeves
    2. Bearing cover (intake)
    3. Screw, M6 x 70
    4. Bearing cover
    5. Screw, M6 x 35
    6. Bearing cover (outlet)
    7. Bearing surfaces (oil with engine oil)
    1. Direction of travel
    Fig 33: Identifying Camshaft Mount (Cylinders 5 To 8)
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36. Move both hydraulic valves for camshaft control into installation position and fit them. -3 and 4- 
    1. Screw, M12 Tighten fully after setting timing  .
    2. Camshaft controller with integrated hexagon for countering
    3. Camshaft control hydraulic valve
    4. Screw, M5 x 12
    Fig 34: Identifying Camshaft Adjustment Screws

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37. Fit threaded peg for tensioning and guide rails if necessary. -1 and 2- 
    1. Threaded peg
    2. Threaded peg
    3. Guide rail
    4. Tensioning rail
    5. Chain tensioner with sealing ring
    6. Pin (for locking the oil-pump tensioning rail)
    1. Direction of travel
    Fig 35: Identifying Timing Chain And Chain Guide
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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-  .
    1. Double-chain camshaft drive
    2. Camshaft sprocket
    3. Screw, M12 Tighten fully after setting timing  .
    4. Deflector rail
    5. Screw, M8 x 35
    6. Camshaft-to-camshaft guide pad
    1. Direction of travel
    Fig 36: Identifying Timing Chain, Sprockets And Tensioning Rail
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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. → INSTALLING TIMING-CASE COVER .
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
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.
    1. Sealant application (geometry, 1-mm bead of sealant)
    2. Sealant application - Doboseal 224N (999.915.573.43, status 04/10)
    1. Direction of travel
    Fig 37: Identifying Oil Guide Housing Sealant Applying Area
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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
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- 
    1. Screw, M6 x 20
    2. Joint flange
    3. Sealing ring
    4. Oil guide housing to lower part of crankcase - aluminum screw 
    5. Oil level sensor
    6. Oil level sensor to oil guide housing (steel screw)
    7. Timing-case cover to oil guide housing - aluminum screw 
    Fig 38: Identifying Oil Guide Housing With Accessories

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51. Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace sealing rings. → Oil lines on naturally aspirated engine → Oil lines, intake pipe on naturally aspirated engine 
    Fig 39: Identifying Oil Lines - Naturally Aspirated Engine

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    Fig 40: Identifying Oil Lines, Intake Pipe - Naturally Aspirated Engine

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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 -2 and 3-  .
    1. Screw, M6 x 20
    2. Joint flange
    3. Sealing ring
    4. Oil guide housing to lower part of crankcase - aluminum screw 
    5. Oil level sensor
    6. Oil level sensor to oil guide housing (steel screw)
    7. Timing-case cover to oil guide housing - aluminum screw 
    Fig 41: Identifying Oil Guide Housing With Accessories
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53. Fit oil level sensor (turn carefully when inserting sensor). -5 and 6- 
54. Fit oil pan with reusable seal and tighten evenly and in diagonally opposite sequence.
    Fig 42: Identifying Oil Pan

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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
    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)
    Fig 43: Supporting Engine

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    1. Water pump pulley
    2. Screw, M8 x 16
    3. Vibration damper
    4. Screw, M18 x 1.5 x 72; use new screw
    5. Power-steering pump pulley
    6. Screw, M8 x 16
    7. Tandem pump pulley
    Fig 44: Identifying Water Pump Pulley
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59. Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see → INSTALLING HIGH-PRESSURE PUMP .
60. Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it. → INSTALLING VACUUM PUMP
    1. Vacuum pump
    2. Screw, M6 x 25
    3. O-ring
    4. O-ring
    Fig 45: Identifying Vacuum Pump, O-Ring And Screws
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61. Fit spark plugs if necessary. → 287020 REMOVING AND FITTING SPARK PLUGS
62. Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see → INSTALLING CYLINDER HEAD COVER
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.
    1. Thermostat housing
    2. Screw, M6 x 25
    3. Screw, M6 x 25; screwed to fuel high-pressure distribution pipe
    4. Seal for thermostat housing; replace
    5. Thermostat insert; including electric heating element
    Fig 46: Identifying Thermostat Housing And Coolant Regulator Screws

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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)
66. 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!
    1. Heater coolant pipe
    2. M6 screw
    3. Sealing ring
    4. Screw plug, M16 x 1.5
    5. M6 screw
    6. Coolant guide tube (collection pipe)
    7. Metal seal
    8. Stopper
    Fig 47: Identifying Heater Coolant Pipe, Coolant Guide And Screws
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67. Fit the water pump. Fit pulley for water pump. For details, see → INSTALLING COOLANT PUMP
68. Fit oil pressure sensor with adapter. Replace sealing rings.
    1. Oil pressure sensor adapter
    2. O-ring
    3. Oil-pressure sender with temperature sensor
    4. Screw, M6 x 40
    5. Stopper
    6. Sealing ring
    1. Direction of travel
    Fig 48: Identifying Oil Pressure Sensor And Adapter
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69. Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor -1-  .
    Fig 49: Identifying Auxiliary Units And Engine Mounting Left Bracket

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70. Fit bearing console on the right. -1- 
    Fig 50: Identifying Auxiliary Units And Engine Mounting Right Bracket

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71. Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position. → Installing Engine Mounting 
72. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
    1. M6 screw; securing coolant line to collection pipe
    2. Coolant pipe
    3. Connection piece screw
    4. Connection piece on generator
    5. Coolant supply hose for oil/coolant heat exchanger
    6. Coolant supply hose to generator
    Fig 51: Identifying Naturally Aspirated Engine Coolant Supply
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73. Fit the generator and crash support. For details, see → INSTALLING GENERATOR
    1. Generator
    2. Screw, M8 x 95
    3. Screw, M8 x 35
    4. Bores for screws, M8 x 95
    1. View
    Fig 52: Identifying Generator Screws
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74. Fit deflection rollers and belt tensioner and press on cover.
    1. Deflection roller
    2. Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning lever
    3. M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and timing-case cover at the console
    4. Deflection roller
    5. Dual poly-V-belt
    Fig 53: Identifying Engine Drive Belt

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75. Fit crankshaft sealing ring on flywheel side. See → INSTALLING CRANKSHAFT
76. Fit coolant hosing and secure clamps.
    1. M6 screw; securing coolant line to collection pipe
    2. Coolant pipe
    3. Connection piece screw
    4. Connection piece on generator
    5. Coolant supply hose for oil/coolant heat exchanger
    6. Coolant supply hose to generator
    Fig 54: Identifying Coolant Supply Line - Naturally Aspirated Engine
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Connection piece on generator
    2. Connection piece screw
    3. Screw, M6 x 20
    4. Coolant return line
    5. Coolant return hose assembly
    6. Holder
    7. M6 screw Aluminum screw  ; always use new aluminum screws
    8. Clip
    Fig 55: Identifying Coolant Return Line - Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
77. 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.
    1. Vent line
    2. Screw, M6 x 16
    Fig 56: Identifying Ventilation Line Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
78. 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
79. Fit high-pressure line and low-pressure line → High-pressure pump on naturally aspirated engine  . To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.
    Fig 57: Identifying High-Pressure Pump Components - Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
80. Fit high-pressure fuel distribution pipe. For details, see → INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL)
81. Check the DFI high-pressure system for leaks. → 243001 CHECKING FUEL DISTRIBUTION PIPE FOR LEAKS
82. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
    Fig 58: Locating Exhaust Manifold Seal - Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
83. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. -3- 
    1. Engine ventilation line
    2. Oil mist separator line to intake-air distributor
    3. Tank ventilation
    4. Aluminum holder
    5. Aluminum screw (holder); see FigureTiming-case cover
    Fig 59: Identifying Engine Ventilation Line - Naturally Aspirated Engines

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
84. 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
85. Fit oil mist separator. For details, see → Installing Oil Separator 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR .
86. Fit power-steering pump. For details, see installation description → INSTALLATION
87. Fit air conditioning compressor. → INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE
88. Fit pulley for power-steering pump or tandem pump.
    1. Water pump pulley
    2. Screw, M8 x 16
    3. Vibration damper
    4. M18 screw; always use a new screw
    5. Power-steering pump pulley
    6. Screw, M8 x 16
    7. Tandem pump pulley
    Fig 60: Identifying Water Pump Pulley

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
89. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). → INSTALLING DRIVE BELT
90. Fit heat protection panels on generator and on exhaust manifold.
    Fig 61: Locating Heat Protection Panels - V8 Naturally Aspirated Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
91. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.