Part 1
WM 1001Z2 Assembling engine - Turbo
Tools
Technical values
Assembly
Assembling engine
NOTICE
Dirt and contamination
- Risk of damage to units or components
-> Protect components from dirt and contamination.
-> Clean or replace dirty components.
Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E.) for external Torx, (T.) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
Fit all threaded connections according to instructions in the document -> 1X00IN Tightening torques for engine MA170 and MA170 S.
1. Fit crankcase half 4-6 on the engine assembly support.
1.1. Use mounting parts 9590 to secure to the engine adapter 9771.
-> 1001IN Tools for removing units and working on the engine assembly support Tools and Equipment.
Information
- The bearing shells must be allocated according to specifications.
- Observe difference between partial-groove bearings and smooth bearings.
- Coat bearing shells with new engine oil.
Information
Always replace gaskets and O-rings.
- Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).
2. Fit new bearing shells on the crankcase halves. The following markings ensure correct allocation.
2.1. Crankcase half 4-6: Markings on crankshaft. The upper series of letters -1- is for the crankcase.
Allocation starts at the supporting mount ( -SL- ) on the belt side and is read from left to right.
The supporting mount does not have a number, while the main bearings are numbered -HL 1-7- (number 7 is at the flywheel side).
Marking for bearing shell allocation on the crankshaft
2.2. Crankcase 1-3: Markings on crankcase half.
The series of letters -1- is read from left to right.
Allocation starts at the flywheel side and ends at the supporting mount on the belt side.
Marking on crankcase half 1-3
2.3. There are also different types of bearing shells.
Bearing shells fitted on crankcase
2.4. Fit and grease new O-ring on the crankcase sealing face.
3. Insert two thrust washers -1- on the main bearing. The oil grooves must be facing outwards => Thrust washer on crankshaft.
Thrust washer on crankshaft
Position of grooves on thrust washer
Information
- Check guide and tensioning rails for visible and obvious signs of wear before installation and replace if damaged.
- The tensioning rails on cylinder bank 1-3 and 4-6 are identical.
- The guide rails on cylinder bank 1-3 and 4-6 are identical.
- The slots in the cylinder head must be positioned during installation.
4. Install tensioning rail for oil-pump drive chain in crankcase 4-6.
Tensioning rail for oil-pump timing chain
4.1. Fit tensioning rail -1- using a short bearing pin.
=> Tightening torque: 10 Nm (7.5 ftlb.)
Tensioning rail for oil-pump drive in crankcase
Position of bearing pin -4- on tensioning rail for oil-pump drive chain.
Bearing pins on cylinder bank 4-6
5. Fit guide rail for cylinder bank 4-6 and secure in the crankcase with a short bearing pin -2-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
5.1. Place spring -2- on tensioning rail -1- for oil-pump drive chain into the cut-out in the guide rail -3-.
Position of tensioning spring in guide rail
6. Insert crankshaft with timing chains -2 + 3-.
6.1. Engage oil pump gear -1- in the drive chain.
Inserting crankshaft into crankcase half 4-6
7. Fix crankshaft in place using special tool holding bridge 9779 -1-.
7.1. Fit and tighten two fastening screws hand-tight.
Crankshaft holding bridge (9779)
8. Install pistons on cylinder bank 4-6 and connecting rods 1-3.
-> 131020 Removing and installing pistons - Turbo Service and Repair.
9. Fit 14 through-bolt screws (E14, M10 x 195) -1- with new sealing washers -3-.
9.1. Fit protective sleeve 9786 -2- over the screw thread. Slide sealing washer onto the screw. Remove protective sleeve.
Through-bolt screw, sealing washer and protective sleeve
Information
- The sealing faces of the crankcase halves must be completely free of oil, grease and burrs before applying sealant.
- Apply a bead of sealant with a diameter of no more than 1 mm. Always apply sealant to the required area only.
- Join the crankcase halves within max. 5 minutes of applying the bead of sealant.
10. Apply sealing compound to crankcase half 4-6. Observe processing instructions.
10.1. Use Dobotech sealing compound (Part No. 000.043.207.31)!
10.2. Carefully apply a continuous bead of sealant -arrow 1- with a diameter of 1 mm. Follow sealant contour as shown in illustration.
10.3. Remove residual silicone in the crankshaft flange area following installation -arrow 2-.
Applying sealant on crankcase half 4-6
11. Fit rubber sleeves on connecting rods 1-3 ( assembly aid 9795 ) -1- and position vertically.
Connecting rods with assembly aid 9795 (rubber sleeves)
11.1. The restraining straps P221 -1- can be used if necessary. Since only two connecting rods can be fixed in place in this case, the third connecting rod -2- must be held when positioning the crankcase half.
Two connecting rods with restraining strap P221
12. Check guide rail -1- for the oil-pump drive chain on crankcase half 1-3.
Guide rail for oil-pump drive chain
12.1. Replace guide rail -1- in the event of visible or obvious damage. This can be unclipped and clipped in again -arrows-.
Removing and installing guide rail for oil-pump drive chain
Information
- Get another person to help you join crankcase halves 1-3.
13. With the help of a second person, place crankcase half 1-3 on crankcase half 4-6.
14. Fit 14 through-bolt screws and tighten according to the specified tightening torque and sequence.
14.1. => Initial tightening: 5 Nm (3.5 ftlb.)
14.2. => Initial tightening: 12 Nm (9 ftlb.)
14.3. => Tightening torque: 15 Nm (11 ftlb.)
14.4. => Torque angle: 75°
14.5. => Final tightening - torque angle: 75°
Through-bolt screws on crankcase
15. Fit 19 external Torx screws (E10 and E12) for the outer cross bolt connection and tighten according to the specified tightening sequence.
15.1. Three M8 x 35 screws, item -15, 16, 17-.=> Initial tightening: 5 Nm (3.5 ftlb.)
=> Torque angle: 70°
15.2. One M8 x 120 screw, item -33-.
=> Tightening torque: 33 Nm (24 ftlb.)
15.3. 15 screws - one M6 x 40 -18- , 14 M6 x 25 -19-32-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Outer cross bolt connection
16. Fit and tighten two mounting parts 9590 for bolting crankcase half 1-3 to the engine support.
17. Install pistons for cylinder bank 1-3.
-> 131020 Removing and installing pistons - Turbo Service and Repair.
18. Turn the crankshaft clockwise a number of times at the flange using turning device 9773 in order to check for smooth operation and correct function.
18.1. Then, turn the crankshaft so that none of the pistons are at TDC position.
19. Fit crankshaft sealing rings at the flywheel and drive side.
-> 135919 Removing and installing crankshaft sealing ring - flywheel side - Turbo 135919 Removing And Installing Crankshaft Sealing Ring - Flywheel Side - Turbo.
-> 137419 Removing and installing crankshaft sealing ring - belt side 137419 Removing and installing crankshaft sealing ring - pulley side.
20. Fit tensioning rail for cylinder bank 4-6 using a long bearing pin -3-.
Bearing pins on cylinder bank 4-6
20.1. Fit tensioning rail for cylinder bank 1-3.
20.2. Secure guide rail for cylinder bank 1-3 in the crankcase with a long bearing pin -1-.
Bearing pins on cylinder bank 1-3
20.3. Tighten bearing pins to the specified torque: 10 Nm (7.5 ftlb.).
21. Fit the oil guide (oil plate) -1- using six external Torx screws M6 x 20 -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Oil guide (oil plate) on crankcase
22. Install oil pump.
-> 172019 Removing and installing oil pump Service and Repair.
23. Install coolant pipe -1- for the coolant pump.
23.1. Fit and tighten two external Torx screws (E10, M6 x 12) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
Coolant pipe for coolant pump
24. Install upper part of oil pan.
-> 175019 Removing and installing oil pan Service and Repair.
25. Install oil lines in the oil pan.
25.1. Install supply line -5- by screwing in and tightening three external Torx screws (E10, M6 x 16) -2-.
25.2. Fit return lines -1 and 3- for the turbocharger by screwing in and tightening two external Torx screws (E10) M6 x 16 -2- and one (E10) M6 x 12 on each -4-.
Oil lines in the oil pan
26. Install lower part of oil pan.
-> 175019 Removing and installing oil pan Service and Repair.
27. Insert 12 displacement bodies -1- on cylinder bank 1-3.
Piston marking and displacement bodies on cylinder bank 1-3
Information
- Always guide timing chains with your hand when turning the crankshaft.
28. Fit cylinder head 1-3 and 4-6.
-> 157019 Removing and installing cylinder head Service and Repair.
29. Pull timing chain 1-3 out of the chain slot and fit oil supply valve for vacuum pump -1- on the cylinder head with a new O-ring -2-. Engage timing chain at the valve.
Oil supply valve on vacuum pump for brake booster
30. Hold the tensioning rail for cylinders 1-3 -1- using a pair of flat-nosed pliers -3- and use a socket-wrench insert -4- to screw in the bearing pin -2-.
Holding tensioning rail
30.1. Secure guide rail for cylinders 4-6 in the cylinder head with a short bearing pin.
30.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ftlb.).
31. Check installation position of tensioning rail for oil-pump drive chain and guide rail again.
Tensioning rail for oil-pump drive chain and guide rail
32. Install solenoid hydraulic valves with new O-rings for camshaft control.
32.1. Tighten two external Torx screws (E8) M5 x 12 on each valve.
=> Tightening torque: 8 Nm (6 ftlb.)
33. Install camshafts.
-> 150520 Removing and installing camshafts (includes setting timing) Service and Repair.
34. Install cylinder head cover.
-> 158219 Removing and installing cylinder head cover - Turbo Service and Repair.
35. Fit cover for positive crankcase ventilation. Replace seals.
35.1. Fit cover for cylinder bank 1-3 -1- with new seals -2 + 3- and secure with three external Torx screws M6 x 20 -4-.
Cover on positive crankcase ventilation 1-3
35.2. Fit cover for cylinder bank 4-6 -1- with a new O-ring -2- and secure with two external Torx screws M6 x 20 -3-.
Cover on positive crankcase ventilation 4-6
36. Fit spark plugs.
-> 287020 Removing and installing spark plugs - Turbo Service and Repair.
37. Install bar ignition modules.
-> 282019 Removing and installing bar ignition module - Turbo Service and Repair.