Assembly

Assembling engine

ATTENTION
Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

Note:
^ All O-rings and seals (shaft seals) and micro-encapsulated screws or lock nuts must be replaced.

Note:
^ Replace all O-rings and grease shaft seals lightly with Optimol MP3 or Kluber Syntheso Glep.

Note:
^ The O-rings for the spark-plug recesses must be replaced.

Note:
^ Re-insert flat-base tappets in the fitted bores in which they were positioned before the disassembly. The flat-base tappets have been run in in the fitting bores in the housing and therefore may not be switched.

The engine is assembled in reverse order to the disassembly.
Components that are not replaced must be cleaned.
Markings on crankcase:





Engine number





Cylinder arrangement

1. Fit bearing cover for intermediate shaft.
2. Fit air/oil separator (swirl pots) and oil suction tube.





3. Install oil pan. Apply a bead of sealant, Loctite 5900, to the cleaned and greased oil pan and secure with 13 Torx screws from the inside out. Tightening torque: 10 (7.5 ft lb.) Nm
4. Install new oil filter using special tool oil filter spanner 9204.





5. Fit lower guide and tensioning rail screws.





6. Screw in aluminum screw plug (M27) for the assembly bore (piston pin).
7. Fit oil pump with housing.





Note:
^ Cylinder-head gaskets are identical parts, lay them down with the TOP identification facing upwards.

8. Fit cylinder head.

ATTENTION
Interchanged or dirty flat-base tappets.
^ Damage to engine components
^ The components have been run in in the fitting bores in the housing, therefore do not interchange them.
^ Pay attention to cleanliness.

9. Install flat-base tappets.
10. Install camshaft.
11. Fit tandem pump.





12. Install cylinder head cover.
13. Fit cylinder head 1-3.

ATTENTION
Interchanged or dirty flat-base tappets.
^ Damage to engine components
^ The components have been run in in the fitting bores in the housing, therefore do not interchange them.
^ Pay attention to cleanliness.

14. Install flat-base tappets.
15. Install camshaft.
16. Install cylinder head cover.
17. Install spark plugs.





18. Fit support for servo lines.





19. Fit transport eyebolt.





20. Fit all plastic components that have been removed (clips, support, etc.).
21. Fit brackets for oxygen sensor cable.





22. Fit coolant adapter.





23. Fit solenoid hydraulic valves for camshaft adjustment, Refer to Installing hydraulic valve for camshaft timing'.
24. Install thermostat housing.





25. Fit coolant pump.





26. Fit coolant lines.





27. Fit crankshaft pulse sender.





28. Fit ignition coils.





29. Fit coolant guide housing.





30. Tiptronic only: Fit clip for guide belt.





31. Fit engine mounting.





32. Fit crankshaft belt pulley retaining device 9593.





33. Fit engine ground lead on cylinder 1-3.





34. Fit deflection roller.





35. Fit both hall senders.





36. Fit flange for positive crankcase ventilation.





37. Install oil pressure sender.





38. Coat spacer sleeve with acid-free grease at the base and insert it.
39. Install oil-level sensor.





40. Fit knock sensors.





41. Fit starter.





42. Fit secondary air pump.





43. Fit oil mist collector. Fix hose with spring band clamp.





44. Fit oil/water heat exchanger.





45. Fit engine wire harness.








46. Fit terminal 50 starter line.





47. Fit terminal 30 starter line.





48. Fit positive crankcase ventilation line.
49. Fit power-steering pump support.





50. Fit power-steering pump.





51. Tighten union nut for servo pressure line.





52. Fit oil filler neck.





53. Fit generator and deflection roller.





54. Fit B+ wire on generator.





55. Connect cable plug to generator.
56. Fit cover for drive belt.





57. Fit intake-air distributor.





58. Fit support for servo lines. Clip oxygen sensor line into support.





59. Connect cable plug for carbon canister solenoid valve.
60. Connect cable plug for all fuel injectors.
61. Push on cable plug for engine compartment temperature sensor.
62. Connect cable plug for the solenoid valves.
63. Fit pulley for power-steering pump.





Assembling engine, touching up

Manual transmission:
1. Install flywheel..
2. Fit clutch
3. Install drive plate for converter.
4. Remove exhaust manifold.
5. Fit transmission.
6. Install engine.
7. Fill in engine oil. Unscrew oil drain plug (hexagon socket a/f 8).