Part 2
WM 100137 Disassembling and assembling engine
Assembling engine
CAUTION
Risk of damage due to particles of dirt.
- Danger of material damage due to blocked oil bores/oil ducts.
-> 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.
Information
- All O-rings and seals (shaft seals), micro-encapsulated, coated screws or lock nuts must be replaced.
Information
- Replace all O-rings and grease shaft seals lightly with Optimol MP3 or Kluber Syntheso Glep.
Information
- The O-rings for the spark-plug recesses must be replaced.
Information
- 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
Engine number, example of 3.8 ltr. engine
Cylinder arrangement
Cylinder arrangement
1. Fit bearing cover for intermediate shaft -> 152119 Removing and installing bearing cover for intermediate shaft - section on "Installing" 152119 Removing and installing bearing cover for intermediate shaft - M96/26.
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 Nm (7.5 ftlb.)
4. Install new oil filter using special tool oil filter spanner 9204.
5. Fit lower guide and tensioning rail screws.
6. Screw in aluminium screw plug (M27) for the assembly bore (piston pin).
7. Fit oil pump with housing.
Information
- Cylinder-head gaskets are identical parts, lay them down with the TOP identification facing upwards.
8. Fit cylinder head 4-6 -> 157019 Removing and installing cylinder head 157019 Removing and installing cylinder head.
CAUTION
Interchanged or dirty bucket tappets.
- Damage to engine components.
-> The components have been run in in the fitting bores in the housing, therefore do not interchange them.
-> Absolute cleanliness is essential.
9. Install flat-base tappets 4-6 -> 157019 Removing and installing cylinder head - section on "Subsequent work" 157019 Removing and installing cylinder head.
10. Install camshaft 4-6 -> 150520 Removing and installing camshaft - section on "Installing" 150520 Removing and installing camshaft (includes adjusting timing) - engine removed.
11. Fit tandem pump.
12. Install cylinder head cover 4-6 -> 158220 Removing and installing cylinder head cover - engine removed - section on "Installing" Removal and Replacement.
13. Fit cylinder head 1-3 -> 157019 Removing and installing cylinder head 157019 Removing and installing cylinder head.
CAUTION
Interchanged or dirty bucket tappets.
- Damage to engine components.
-> The components have been run in in the fitting bores in the housing, therefore do not interchange them.
-> Absolute cleanliness is essential.
14. Install flat-base tappets 1-3-> 157019 Removing and installing cylinder head - section on "Subsequent work" 157019 Removing and installing cylinder head.
15. Install camshaft 1-3 -> 150520 Removing and installing camshaft - section on "Installing" 150520 Removing and installing camshaft (includes adjusting timing) - engine removed.
16. Install cylinder head cover 1-3 -> 158220 Removing and installing cylinder head cover - engine removed - section on "Installing" Removal and Replacement.
17. Install spark plugs -> 287020 Removing and installing spark plugs - section on "Installing" Service and Repair.
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 -> 153719 Removing and installing solenoid hydraulic valve for camshaft adjustment - section on "Installing" Service and Repair.
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 -> 272219 Removing and installing generator - section on "Installing" Service and Repair.
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.
Subsequent work for assembling engine
Assembling engine, touching up
Manual transmission:
1. Install flywheel.-> 136019 Removing and installing flywheel Removal and Replacement.
2. Fit clutch -> 305019 Removing and installing clutch 30501950 Removing and installing clutch.
Tiptronic transmission:
3. Install drive plate for converter -> 136319 Removing and installing drive plate for converter Removal and Replacement.
4. Remove exhaust manifold -> 261019 Removing and installing exhaust manifold Service and Repair.
5. Fit transmission -> 343527 Removing and refitting transmission 34352750 Removing and mounting transmission.
6. Install engine -> 100119 Removing and installing engine 100119 Removing and installing engine.
7. Fill in engine oil. Unscrew oil drain plug (hexagon socket a/f 8) -> 170155 Engine oil and oil filter change Removal and Replacement.
