Assembling Engine

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

Information

Detailed information on

tightening torque,
tightening sequence,
component allocations, classification,
surface treatment,
replacing parts,
Applying sealant

can be found in the following documents:

> WM, 1X00IN TECHNICAL VALUES

> 2X00IN TECHNICAL VALUES

> 3X00IN TECHNICAL VALUES, TRANSMISSION

Information

Do not remove stoppers used to close off connections during disassembly until just before fitting the affected component.

Information

Replace worn bearing shells.

Information

Sealing faces must be free of oil and grease.

Clean components and perform visual inspection. Replace damaged components.
1. 1.1 Clean sealing faces.
2. 1.2 Clean the thread and re-cut if necessary.
Install knock sensor.
> Removing and installing knock sensor (V6 Turbo)
Install piston spray nozzles -2- .

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Piston spray nozzles on cylinder block
1. 3.1 Position piston spray nozzles -2- .
2. 3.2 Replace screws on piston spray nozzles -1- .
3. 3.3 Fit and tighten new screws on piston spray nozzles -1- .
> Initial tightening 10 Nm (7.5 ftlb.)

> Final tightening + 45°
Install crankshaft with new bearing shells into the cylinder block.
> Removing and installing crankshaft
Install pistons and connecting rods with new bearing shells.
> Removing and installing pistons
Install balance shaft.
> Removing and installing balance shaft (V6 Turbo)
Assemble cylinder heads.
1. 7.1 Install new valve-stem seals.
  > Replacing valve-stem seals (V6 Turbo)
2. 7.2 Install valves.
  > Removing and installing valves (V6 Turbo)
3. 7.3 Install valve lifters (hydraulic tappets).
> Removing and installing valve lifters (hydraulic tappets) (V6 Turbo)
Install both cylinder heads with new cylinder-head gaskets.
> Removing and installing cylinder head
Install camshafts in cylinder head covers.
> Removing and installing camshaft (V6 Turbo)
Install both cylinder head covers.
> Removing and installing cylinder head cover (V6 Turbo)
Install guide and tensioning rails.
> Removing and installing guide and tensioning rails (V6 Turbo)
Install chain tensioner.
> Removing and installing chain tensioner
Install timing chain.
> Removing and installing timing chain (V6 Turbo)
Install brake booster vacuum pump.
V6 monoturbo:

> Removing and installing brake booster vacuum pump (V6 monoturbo)

V6 biturbo:

> Removing and installing brake booster vacuum pump (V6 biturbo)
Install coolant control valve -3- .

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Coolant control valve
1. 15.1 Fit and position coolant control valve -3- on coolant pipe -4- .
2. 15.2 Fit and tighten screws on coolant control valve -2- .
  > Tightening torque 9 Nm (6.5 ftlb.)
3. 15.3 Connect vacuum hose -1- .
Install coolant pump.
> Removing and installing coolant pump (V6 Turbo)
Install coolant regulator (thermostat insert).
> Removing and installing coolant regulator (V6 Turbo)
Install coolant flanges on left and right cylinder bank.

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Coolant flanges
1. 18.1 Position coolant flanges.
2. 18.2 Fit and tighten screws -1 and 2- .
  > Tightening torque 9 Nm (6.5 ftlb.)
3. 18.3 Fit and tighten screws -3- .
> Tightening torque 9 Nm (6.5 ftlb.)
Replace crankshaft sealing rings on both sides of the engine.
Flywheel side:

> Replacing crankshaft-flywheel sealing ring

Belt side:

> Replacing sealing ring for crankshaft pulley
Install crankcase cover.
> Removing and installing crankcase cover (V6 Turbo)
Install lower chain housing cover.
> Removing and installing lower chain housing cover (V6 Turbo)
Install oil windage tray -2- .

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Oil plate
1. 22.1 Position oil windage tray -2- on cylinder block.
2. 22.2 Replace screws for oil windage tray -1 and 3- .
3. 22.3 Fit screws securing oil windage tray to cylinder block -1- and tighten crosswise.
  M6 x 18 (3 ea.)
  
  > Initial tightening 3 Nm (2 ftlb.)
  
  > Final tightening + 90°
  
  M6 x 30 (13 ea.)
  
  > Initial tightening 3 Nm (2 ftlb.)
  
  > Final tightening + 90°
4. 22.4 Tighten screws securing chain housing cover to oil windage tray -3- .
> Initial tightening 3 Nm (2 ftlb.)

> Final tightening + 90°
Install oil pump.
> Removing and installing oil pump (V6 Turbo)
Install oil guide housing.
> Removing and installing oil guide housing (V6 Turbo)
Install oil pan.
> Removing and installing oil pan (V6 Turbo)
Install intake-air distributor.
> Removing and installing intake-air distributor (V6 Turbo)
Install oil pressure control valve.
> Removing and installing oil pressure control valve
Install hall-sender rotor.
> Removing and installing hall-sender rotor
Install drive plate.
> Removing and installing drive plate
Install crankshaft vibration damper.
> Removing and installing crankshaft vibration damper (V6 Turbo)
Install deflection roller for drive belt for generator -1- .

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Deflection roller for drive belt for generator
1. 31.1 Position deflection roller -1- .
2. 31.2 Fit and tighten screw for deflection roller -3- .
  > Tightening torque 25 Nm (19 ftlb.)
3. 31.3 Fit dust boot -2- .
Install generator bracket -1- .

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Generator bracket
1. 32.1 Position generator bracket -1- .
2. 32.2 Fit and tighten new screws -2- .
> Initial tightening 8 Nm (6 ftlb.)

> Final tightening + 90°
Install air-conditioning compressor bracket -5- .

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Air-conditioning compressor bracket (shown on V6 monoturbo)
1. 33.1 Position air-conditioning compressor bracket -5- .
2. 33.2 Fit and tighten new screws for air-conditioning compressor bracket -4- .
  > Initial tightening 8 Nm (6 ftlb.)
  
  > Final tightening + 90°
3. 33.3 Install tensioning roller -3- .
  1. 33.3.1 Position tensioning roller -3- .
  2. 33.3.2 Replace screw on tensioning roller -2- for drive belt for air-conditioning compressor.
  3. 33.3.3 Fit and tighten new screw on tensioning roller -2- .
    > Tightening torque 25 Nm (19 ftlb.)
  4. 33.3.4 Fit dust boot -1- .
Install generator.
> Removing and installing generator (V6 Turbo)
Install air-conditioning compressor.
V6 Turbo:

> Removing and installing air conditioning compressor

V6 Hybrid:

> Removing and installing air conditioning compressor
Install drive belt.
> Removing and installing drive belt (V6 Turbo)
Install tank vent valve.
V6 monoturbo:

> Removing and installing tank vent valve (V6 monoturbo)

V6 biturbo:

> Removing and installing tank vent valve (V6 biturbo)
Install solenoid hydraulic valves for valve lift adjustment.
> Removing and installing solenoid hydraulic valve for valve lift adjustment
Install fuel injectors.
> Removing and installing fuel injector
Install fuel collection pipe.
> Removing and installing fuel collection pipe (V6 Turbo)
Install piston spray nozzle control valve.
> Removing and installing piston spray nozzle control valve (V6 Turbo)
Install oil/water heat exchanger.
> Removing and installing oil/water heat exchanger (V6 Turbo)
Install oil filter housing.
V6 monoturbo:

> Removing and installing oil filter housing (V6 monoturbo)

V6 biturbo:

> Removing and installing oil filter housing (V6 biturbo)
Install the oil separator.
> Removing and installing oil separator (V6 Turbo)
Install spark plugs.
> Removing and installing spark plugs
Install ignition coils.
> Removing and installing ignition coils (V6 Turbo)
Install upper chain housing cover.
> Removing and installing upper chain housing cover (V6 Turbo)
Install high-pressure pump.
> Removing and installing high-pressure pump (V6 Turbo)
Install turbocharger.
V6 monoturbo:

> Removing and installing turbocharger (V6 monoturbo)

V6 biturbo:

> Removing and installing turbocharger (V6 biturbo)
Connect all vacuum hoses in accordance with the markings.