Assembling Engine

NOTIFICATION 

Interchanged or dirty bucket tappets 

• Scoring on cylinder head 
  1. → Since the bucket tappets have been run in the fitting bores, do not interchange them.
  2. → Absolute cleanliness is essential.

Information 

• Stoppers must not be removed from the closed-off connections until the relevant component is fitted. 

Information 

Worn bearing shells must be replaced.

Information 

Sealing faces must be free of oil and grease.

1. Clean components and perform visual inspection. Replace damaged components.
   1. 1.1  Clean all sealing faces.
   2. 1.2  Clean the thread and re-cut it if necessary.
2. Install crankshaft.

   > 134819 - REMOVING AND INSTALLING CRANKSHAFT (R4)

3. Assemble pistons.

   > 131037 - DISASSEMBLING AND ASSEMBLING PISTONS

4. Install pistons.

   > 131020 - REMOVING AND INSTALLING PISTONS (R4)

5. Install oil guide housing.

   > 174619 - REMOVING AND INSTALLING OIL GUIDE HOUSING (R4)

6. Install oil pump.

   > 172019 - REMOVING AND INSTALLING OIL PUMP (R4)

7. Install the oil pan.

   > 175019 - REMOVING AND INSTALLING OIL PAN (R4)

8. Assemble cylinder head.
   1. 8.1  Install new valve-stem seals.

      > 156356 - REPLACING VALVE-STEM SEALS (R4)

   2. 8.2  Install valves.

      > 156119 - Removing and installing valves (R4)  , Refer to the appropriate service information.

   3. 8.3  Install valve lifters.

      > 155919 - Removing and installing valve lifters (R4)  , Refer to the appropriate service information.

9. Install cylinder head.

   > 157019 - REMOVING AND INSTALLING CYLINDER HEAD (R4)

10. Install cylinder head cover.

    > 158219 - REMOVING AND INSTALLING CYLINDER HEAD COVER (R4)

11. Install camshaft actuators.

    > 158419 - REMOVING AND INSTALLING CAMSHAFT ACTUATOR (R4)

12. Install balance shafts.

    > 138555 - REPLACING BALANCE SHAFTS (R4)

13. Install guide and tensioning rails.

    > 154719 - REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS (R4)

14. Install chain tensioner.

    > 153619 - REMOVING AND INSTALLING CHAIN TENSIONER (R4)

15. Install timing chain.

    > 153519 - REMOVING AND INSTALLING TIMING CHAIN (R4)

16. Install chain housing cover.

    > 153319 - REMOVING AND INSTALLING CHAIN HOUSING COVER (R4)

17. Install vibration damper.

    > 137519 - Removing and installing crankshaft vibration damper (R4)  , Refer to the appropriate service information.

18. Install hall sender.

    > WM, 283919 REMOVING AND INSTALLING CAMSHAFT SENSOR (R4)

19. Install the oil separator.

    > 105519 - REMOVING AND INSTALLING OIL SEPARATOR (R4) 

20. Install hydraulic valve for valve lift switchover.

    > 155519 - REMOVING AND INSTALLING HYDRAULIC VALVE FOR VALVE LIFT SWITCHOVER (R4)

21. Fit spark plugs.

    > 287020 - REMOVING AND INSTALLING SPARK PLUGS (R4)

22. Install ignition coils.

    > 282020 - REMOVING AND INSTALLING IGNITION COILS (R4)

23. Install pressure-regulating valve.

    > 172619 - REMOVING AND INSTALLING PRESSURE-REGULATING VALVE (R4)

24. Install oil-pressure sender.

    > 170419 - REMOVING AND INSTALLING OIL-PRESSURE SENDER (R4)

25. Install knock sensor.

    > 287219 - REMOVING AND INSTALLING KNOCK SENSOR (R4)

26. Install pulse sender.

    > 287319 - REMOVING AND INSTALLING PULSE SENDER

27. Install coolant pump.

    > 195019 - REMOVING AND INSTALLING COOLANT PUMP (R4)

28. Install drive belt for coolant pump.

    > 194819 - REMOVING AND INSTALLING DRIVE BELT FOR COOLANT PUMP (R4)

29. Install oil cooler bracket.

    > 176719 - REMOVING AND INSTALLING BRACKET FOR OIL COOLER (R4)

30. Install fuel injectors.

    > 244019 - REMOVING AND INSTALLING FUEL INJECTOR (R4)

31. Install fuel collection pipe.

    > 243019 - REMOVING AND INSTALLING FUEL COLLECTION PIPE (R4)

32. Install intake-air distributor.

    > 244619 - REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR (R4)

33. Install the high-pressure pump.

    > 246319 - REMOVING AND INSTALLING HIGH-PRESSURE PUMP (R4)

34. Install turbocharger.

    > 213020 - Removing and installing turbocharger (R4)  , Refer to the appropriate service information.