Part 2
Disassembling and assembling V6 DFI engine (Continued)
Assembling V6 DFI engine
Caution:
Leaks due to components being at too low a temperature or at different temperatures!
^ If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
-> Components must have reached at least 17 degrees 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.
Information:
^ Detailed instructions for installing pistons must be observed at all times.
^ The cast lugs, the twist lock (locking lugs) -1- and the flat side of the piston crown -2- are on the same side.
Arrangement of pistons and connecting rods
1. Install crankshaft.
Crank drive on V6 DFI engine
1 - Crankshaft bearing covers
2 - Internal serration screw on crankshaft bearing cover -> Initial tightening: 30 Nm (22 ftlb.) -> Torque angle: 180°
3 - Bearing shell
4 - Thrust washer for bearing cover 5
5 - Crankshaft
6 - Drive plate for inductive pickup
7 - Countersunk screw on drive plate for inductive pickup -> Initial tightening: 10 Nm (7.5 ftlb.) -> Torque angle: 90°
8 - Oil spray jet
Information:
^ Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust
^ Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side.
^ The twist locks or retaining lugs are on the same side.
^ Bearing screws must be replaced.
^ Bearing shells must be replaced. Use only identical color markings
1.1. Oil bearing shells with engine oil and place them on the crankshaft/crankcase. Make sure that the twist lock -Twist locks is inserted cleanly in the crankcase.
Twist locks
1.2. Always replace bearing shells. Observe relevant classification.
1.3. Fit thrust bearing no. 5 with thrust washers -4- (insert using grease, lubricating groove facing outwards) and then fit the remaining bearing covers.
1.4. Tap crankshaft bearing covers on securely as far as they will go using a rubber hammer so that the tightening torque will be accurate.
1.5. Internal serration screws on the crankshaft bearing covers -2- must always be replaced and screwed in by hand.
1.6. Then gradually tighten the bearing covers from the inside out to the specified torque -2-.
1.7. As a test, turn the crankshaft several times to check that it turns smoothly.
1.8. If the drive plate -6- for the inductive pickup (speed sender) was removed from the crankshaft, the drive plate must always be replaced.
1.8.1. Tighten the countersunk screws -7- on the drive plate to the specified tightening torque.
2. Install piston.
Overview of piston/connecting rod
1 - Piston rings (move gap by 120 degrees)
2 - Pistons
3 - Circlip
4 - Connecting rod
5 - Connecting rod bearings must always be replaced. Observe relevant classification.
6 - Connecting rod bearing cap
7 - Connecting rod bolts -> Initial tightening: 30 Nm (22 ftlb.) -> Torque angle: 900
8 - Cylinder block
9 - Piston pins
2.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool funnel T10333 can be positioned flat on the cylinder block.
Dowel sleeve on cylinder block
Pfeil - Dowel pin
2.2. Oil the piston well and insert it into the funnel.
2.3. Align all pistons so that the deep valve recesses -1 and 2- are facing the middle of the cylinder block and the arrows -3- on the pistons are facing the vibration damper.
Installation direction of pistons on V6 DFI engine
1 - Valve recesses on cylinders 1, 3 and 5
2 - Valve recesses on cylinders 2, 4 and 6
3 - Arrow pointing towards vibration balancer
2.4. Position the piston funnel on the cylinder block and align it so that the high edge -arrow- is facing the middle of the cylinder block.
Positioning piston funnel on cylinder block
2.5. Slide piston fully into the cylinder bore.
2.5.1. Turn the crankshaft back and forth if necessary.
2.6. Insert dowel sleeves back into the bore holes -arrow-.
2.7. Oil connecting-rod bearing shells -5-.
Information:
^ Always replace the connecting-rod bearing shells and oil them before inserting them into the bearing covers.
^ The connecting-rod big end and connecting-rod bearing caps must be aligned according to the cast lugs -B and C-. The retaining lugs of the connecting-rod bearing shells are on one side. Connecting-rod bearing caps are legible on alternate sides.
Twist lock
^ Install connecting rod and connecting-rod bearing caps unrestrained. If necessary, remove them again, position the bearing caps by tapping lightly with a plastic hammer and then refit them.
2.8. Assign connecting rod bearing caps correctly and screw in the connecting rod bolts -7- by hand. When doing so, make sure that the locking lugs on the bearing shells are aligned.
2.9. Carefully tap the connecting rod bearing caps -6- with a plastic hammer until they are seated correctly so that the tightening torque will be accurate.
2.10. Tighten all connecting rod bearing screws -7- to the specified tightening torque.
2.11. Turn the crankshaft several times to check that it turns smoothly.
2.12. Align the crankshaft so that the gap -arrow- on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).
Pfeil - Setting of gap on drive plate for inductive pickup (speed sender)
Setting of drive plate for inductive pickup
3. Fit joint flange for vibration balancer.
Crankshaft joint flange
1 - Cylinder block
2 - Vibration balancer joint flange
3 - Hexagon-head bolt on vibration balancer joint flange -> Tightening torque: 10 Nm (7.5 ftlb.)
4 - Straight pin, M8 x 18
5 - Lower timing-case cover
6 - Hexagon-head bolt on lower timing-case cover -> Tightening torque: 8 Nm (6 ftlb.)
3.1. Apply a bead of sealant -arrows- with a thickness of 2 mm.
Applying sealant on joint flange
3.2. Fit assembly fixture T10215 (guide sleeve) -1- on the crank pin -3- to prevent damage to the vibration balancer joint flange.
3.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder block.
Joint flange on front of crankshaft
1 - Assembly fixture (guide sleeve)
2 - Vibration balancer joint flange
3 - Crankshaft flange
3.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
4. Fit vibration balancer for crankshaft.
Brace
4.1. Tighten hexagon-head bolt on crankshaft vibration balancer -> Initial tightening: 100 Nm (74 ftlb.) -> Torque angle: 180°.
5. Position engine to the compression TDC of cylinder 1.
Pfeil - Crankshaft/vibration balancer marking
TDC marking on pulley and housing cover
6. Install oil pump.
Pfeile - Hexagon-head bolt on oil pump -> Tightening torque: 8 Nm (6 ftlb.)
Piston funnel
7. If the oil retaining valve was removed during removal, fit a new sealing ring on the oil retaining valve before inserting it into the crankcase -arrow-.
Pfeil - Oil retaining valve
Oil retaining valve
8. Install cylinder head.
Cylinder head
Pistons of cylinders 1 - 6
1- Tightening sequence for cylinder-head screws -> Initial tightening: 15 Nm (11 ftlb.) -> Tightening 20 torque: 30 Nm (22 ftlb.) -> Torque angle: 180°
8.1. Thoroughly clean all sealing faces before assembly.
8.2. Cylinder head gasket must always be replaced.
8.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and tighten to the specified torque.
8.3.1. Tighten cylinder-head screws to an initial tightening torque of 15 Nm (11 ftlb.).
8.3.2. Tighten cylinder-head screws to 30 Nm (22 ftlb.).
8.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22 ftlb.).
8.3.4. And finally, tighten the cylinder-head screws to a torque angle of 180°.
9. Install hydraulic tappets.
10. Install the camshafts.
Overview of cylinder head on V6 DFI engine
1 - Intake camshaft
2 - Camshaft bearing cover
3 - Outlet camshaft
4 - Hexagon nut on camshaft bearing cover -> Initial tightening: 5 Nm (3.5 ftlb.) Torque angle: 45°
5 - Sealing rings (40 x 1.5)
6 - Timing chain housing
7 - Oval-head screw on timing chain housing
8 - Outlet camshaft controller (marking 32 A)
9 - Intake camshaft controller (marking 24 E)
10 - Hexagon-head bolts on camshaft controllers
11 - Cylinder head height (min. height a=139.9 mm)
12 - Drive gearwheel for high-pressure pump
13 - Bearing shaft
14 - Valves
15 - Dowel sleeve
16 - Cylinder head
17 - Pump tappet
18 - Support element
19 - Valve stem seal
20 - Timing chain
21 - Safety clip
22 - Rocker arm
23 - Valve spring
24 - Valve-spring plate
25 - Valve collets
10.1. Insert the camshafts into the cylinder head in such away that the camshaft guide T10068A fits into the slots on the intake and outlet camshafts at the same time.
Installation position of camshaft
Pfeil -Hexagon for countering the camshaft
10.2. Install intake camshaft. Note the sequence in which the bearing covers are installed.
10.2.1. First fit bearing covers 5 and 9 and tighten the hexagon nuts alternately and crosswise.
10.2.2. Repeat the process for bearing covers 1 and 13.
10.2.3. Repeat the process for bearing cover 5.
10.2.4. Repeat the process for bearing covers 3 and 11.
10.3. Install outlet camshaft. Note the sequence in which the bearing covers are installed. Use the same torque and torque angle as for the intake camshaft.
10.3.1. First fit bearing covers 6 and 10 and tighten the hexagon nuts alternately and crosswise.
10.3.2. Repeat the process for bearing covers 2 and 14.
10.3.3. Repeat the process for bearing cover 8.
10.3.4. Repeat the process for bearing covers 4 and 12.
10.4. Install timing chain housing.
Removing timing chain housing
1 - Cheese head bolt -> Tightening torque: 8 Nm (6 ftlb.)
2 - Timing chain housing
11. Fit timing chains.
Component overview of timing chains
1 - Timing chain housing
2 - Oval-head screw on timing chain housing Tightening torque: 8 Nm (6 ftlb.)
3 - Timing chain
4 - Outlet camshaft controller (marking 32 A)
5 - Sealing ring
6 - Oil pump
7 - Fastening screw on oil pump -> Tightening torque: 8 Nm (6 ftlb.)
8 - Tensioning rail
9 - Chain tensioner on timing chain -> Tightening torque: 40 Nm (30 ftlb.)
10 - Sealing ring (A22 x 27), always replace
11 - Bearing pin on guide rail -> Tightening torque: 10 Nm (7.5 ftlb.)
12 - Sprocket
13 - Drive wheel for timing chain
14 - Hexagon-head bolt -> Initial tightening: 60 Nm (44 ftlb.) -> Torque angle: 90°
15 - Chain tensioner for drive chain
16 - Drive gearwheel for drive chain
17 - Drive chain
18 - Guide rail for drive chain
19 - Bolt for guide rail -> Tightening torque: 10 Nm (7.5 ftlb.)
20 - Fastening screw on guide rail -> Tightening torque: 20 Nm (15 ftlb.)
21 - Hexagon-head bolt on guide rail -> Tightening torque: 23 Nm (17 ftlb.)
22 - Hexagon-head bolts on camshaft controllers -> Initial tightening: 60 Nm (44 ftlb.) Torque angle: 90°
23 - Guide rail for timing chain
24 - Drive gearwheel for high-pressure pump
25 - Intake camshaft controller (marking 24 E)
26 - Valve for outlet camshaft controller
27 - Valve for intake camshaft controller
28 - Guide rail
11.1. Install chain tensioner.
11.2. Install camshaft controllers.
12. Check the timing.
13. Fit upper and lower timing-case cover.
13.1. Fit lower timing-case cover.
Crankshaft joint flange
1 - Cylinder block
2 - Vibration balancer joint flange
3 - Hexagon-head bolt on vibration balancer joint flange
4 - Straight pin, M8 x 18
5 - Lower timing-case cover
6 - Hexagon-head bolt on lower timing-case cover -> Tightening torque: 10 Nm (7.5 ftlb.)
13.2. Fit upper timing-case cover.
Removing and installing vacuum pump
1 - Drive shaft
2 - Upper timing-case cover
3 - Oval-head screw -> Tightening torque: 8 Nm (6 ftlb.)
4 - Oval-head screw on vacuum pump -> Tightening torque: 8 Nm (6 ftlb.)
6 - Seal
7 - Sealing ring
Information:
Installation of oil pan
Check the best-before date on the sealing compound.
The oil pan must be installed within 5 minutes of applying the silicone sealant.
The bead of sealant that is applied must not be thicker than the specified thickness because otherwise excess sealant can get into the oil pan and can block the strainer in the oil pump intake pipe.
Allow the sealant to dry for at least 30 minutes after installing the oil pan. Only then can engine oil be filled in.
14. Install oil pan.
Removing and installing upper timing chain housing cover
1-25 - Hexagon-head bolts on oil pan -> Tightening torque: 12 Nm (9 ftlb.)
15. Install cylinder head cover.
Removing and installing valve cover seal
1 - Cylinder head cover
2 - Cylinder head gasket
3 - Fastening screw on cylinder head cover -> Tightening torque: 10 Nm (7.5 ftlb.)
4 - Lid
16. Install flywheel/drive plate.
16.1. Install dual-mass flywheel on vehicles with manual transmission.
16.2. Remove drive plate on vehicles with automatic transmission.
17. Install oil/water heat exchanger.
Oil-filter housing
1 - Oil-filter housing
2 - Seal must always be replaced
3 - Sealing rings must always be replaced
4 - Oil cooler
5 - Oil cooler cover -> Tightening torque: 25 Nm (19 ftlb.)
6 - Oil pressure switch -> Tightening torque: 20 Nm (15 ftlb.)
7 - Oil filter
8 - Lower part of oil filter -> Tightening torque: 25 Nm (19 ftlb.)
9 - Oil drain plug -> Tightening torque: 10 Nm (7.5 ftlb.)
10 - Hexagon-head bolt on oil/water heat exchanger -> Tightening torque: 23 Nm (17 ftlb.)
18. Install coolant regulator.
Coolant regulator
1 - Thermostat housing
2 - Spring band clamp
3 - Coolant hose
18.1. Fit thermostat housing -1- completely into the cylinder block.
18.2. Slide coolant hose -3- onto the thermostat housing.
18.3. Fasten spring band clamp -2-.
19. Install fuel distribution pipe and fuel injectors.
Fuel distribution pipe for cylinders
1 - Fuel low-pressure line -> Tightening torque: 22 Nm (16 ftlb.) -> Tightening torque: 35 Nm (26 ftlb.)
2 - Cheese head bolts on fuel distribution pipe -> Initial tightening: 30 Nm (22 ftlb.) -> Torque angle: 90°
3 - Fuel injectors
20. Install coolant pump.
Pfeile - Oval-head screw (coolant pump) -> Tightening torque: 8 Nm (6 ftlb.)
Coolant pump
21. Install exhaust manifold.
Pfeile - Hexagon nut on exhaust manifold -> Tightening torque: 25 Nm (19 ftlb.)
Exhaust manifold
22. Install intake-air distributor.
23. Install guide tube for oil dipstick. Sealing ring must always be replaced.
24. Install unit carrier.
Removing and installing unit carrier
1 - Belt tensioner
2 - Cheese head bolt on belt tensioner
3 - Unit carrier
4 - Fit bolt on unit carrier -> Tightening torque: 23 Nm (17 ftlb.)
5 - Cheese head bolt on unit carrier -> Tightening torque: 23 Nm (17 ftlb.)
6 - Dowel sleeve for unit carrier
7 - Deflection roller with fastening screw
8 - Drive belt (poly-rib belt)
9 - Generator
10 - Coolant pump pulley
11 - Drive wheel for air conditioning compressor
12 - Power-steering pump pulley
13 - Crankshaft vibration damper
25. Install the generator.
26. Install hydraulic pump (power-steering pump).
27. Install belt tensioner.
Pfeile - Cheese head bolts on belt tensioner -> Tightening torque: 25 Nm (19 ftlb.)
Belt tensioner
28. Fit and tension the drive belt.
Fitting sequence
1 - Crankshaft vibration balancer
2 - Coolant pump
3 - Drive belt tensioning roller
4 - Air conditioning compressor
5 - Power-steering pump/tandem pump
6 - Generator
7 - Deflection roller
29. Install bar ignition modules.
Removing and fitting ignition coils and spark plugs
1 - Connectors for bar ignition modules
2 - Retaining clips
3 - Engine wire harness
30. Fit engine wire harness.
30.1. Clip in engine wire harness at the rear engine housing using the retaining clips -arrows-.
Pfeile - Retaining clips
Clipping in engine wire harness at the rear
30.2. Connect engine wire harness to the oil/water heat exchanger.
Clipping in engine wire harness at the front left
Subsequent work
1. Remove engine from the mounting bracket.
2. Mount the transmission.
3. Install the engine.
4. Perform a test drive and check for leaks and correct function.
4.1. Clean the engine and carry out a thorough check for leaks after the test drive.