Part 2

WM 1001Z2 Assembling engine - Turbo

Subsequent work

NOTICE

Dirt and contamination

- Risk of damage to units or components

-> Protect components from dirt and contamination.
-> Clean or replace dirty components.

Information

- Grease O-rings, hoses and lines in the cooling system with Kluber plus Gel (Part No. 000.043.205.93).

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).

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. Install upper coolant distributor housing (unit carrier) -1-.
-> 195919 Removing and installing unit carrier (coolant distributor housing) - Turbo 195919 Removing And Installing Unit Carrier (coolant Distributor Housing) - Turbo.





Unit carrier (installed)

1.1. Fit coolant connection piece using three external Torx screws (E12, M8 x 70) -2-.
1.2. Fit unit carrier using two external Torx screws (E12): one M8 x 50 screw -3 (right)- and one M6 x 35 screw -4-.
1.3. Secure coolant pipe for the unit carrier -1- to the cylinder head using two external Torx screws (E10, M6 x 12) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Coolant pipe with hose and connection piece

2. Fit bracket for coolant pump -1- with new O-rings -2 + 3-.





O-rings for coolant pipes at coolant pump

2.1. Fit one M10 threaded bolt (engine carrier mounting) -7- (using two M10 lock nuts).
=> Tightening torque: 5 Nm (3.5 ftlb.)
2.2. Fit the bracket using four external Torx screws: one M8 x 70 (E12) -3- , one M8 x 50 (E12) -4- , one M6 x 20 (E10) -5- and one M8 x 25 (E12) -6-.





Bracket for coolant pump

3. Install housing for coolant regulator.
-> 195519 Removing and installing housing for coolant regulator.
3.1. Fit housing on the unit carrier and secure to the connecting tube for the coolant pump using three external Torx screws (E10, M6 x 25).
3.2. Fit one external Torx screw (E10) M6 x 50.
3.3. Tighten screws one at a time.=> Tightening torque: 13 Nm (9.5 ftlb.)
=> Tightening torque: 13 Nm (9.5 ftlb.)
4. Tighten fastening screws on coolant pump bracket and unit carrier.
4.1. => Tightening torque: 33 Nm (24 ftlb.)
4.2. => Tightening torque: 23 Nm (17 ftlb.) Coolant pump bracket
=> Tightening torque: 13 Nm (9.5 ftlb.)
4.3. Turn the belt tensioner clockwise as far as it will go at the hexagon (a/f 30). Remove screw from the crankcase bore and allow the belt tensioner to slide back to normal position.
5. Fit coolant guide -1-.
5.1. Check moulded seals and replace if necessary.
5.2. Fit and tighten six external Torx screws (E10, M6 x 25) -2-.





Lower coolant guide

6. Fit vibration damper. Secure with a locating pin (8 mm) for countering purposes.
-> 137519 Removing and installing vibration damper - Turbo Service and Repair.
6.1. Fit and tighten six external Torx screws (E12) M8 x 1 x 25 (fine thread).
=> Tightening torque: 60 Nm (44 ftlb.)
7. Install coolant pipe -1- for the coolant regulator housing and secure with one external Torx screw (E10, M6 x 12) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Coolant connection pipe to thermostat housing

8. Install vacuum pump -3- with vacuum line -1-.
-> 477619 Removing and installing vacuum pump.
-> 477755 Replacing vacuum line for brake booster (section at engine) 477755 Replacing vacuum line for brake booster (section at engine).





Vacuum pump

9. Secure vacuum line -1- for brake booster at the oil pan.
-> 477755 Replacing vacuum line for brake booster (section at engine) 477755 Replacing vacuum line for brake booster (section at engine).
9.1. Fit and tighten external Torx screws (E10, M6 x 12) -2-.
=> Tightening torque: 10 Nm (7.5 ftlb.)





Vacuum line for brake booster

10. Install high-pressure pump -6-.
-> 246319 Removing and installing high-pressure pump - Turbo Service and Repair.





High-pressure pump with cover and cylinder head cover

11. Fit fuel lines to high-pressure pump -6-.
11.1. Grease thread with OKS 1700 lubricant (Part No. 000.043.207.36) and tighten union nuts -4 and 5-.
11.2. Fit line bracket using M6 external Torx screws.
11.3. First tighten the union nuts, then the screws on the line bracket.
=> Tightening torque: 20 Nm (15 ftlb.)
=> Tightening torque: 13 Nm (9.5 ftlb.)
12. Fit cover -1- for high-pressure pump.
12.1. Screw in and tighten two external Torx screws (E10) M6 x 25 -2- and one M6 x 40 -3-.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Cover and fuel lines on high-pressure pump

13. Fit heat shield for high-pressure pump using three external Torx screws (E10) M6 x 12.
=> Tightening torque: 13 Nm (9.5 ftlb.)
14. Install coolant regulator with housing cover -1- and intake tube -5-.
14.1. External Torx screws (E10) on housing cover: Tighten three M6 x 50 screws -3- and one M6 x 40 screw -2-.
14.2. Grease new O-rings on the intake tube and fit tube into the coolant regulator housing. Tighten external Torx screws M6 x 12 -4-.
14.3. => Tightening torque: 13 Nm (9.5 ftlb.)





Intake tube and coolant regulator housing

15. Fit exhaust manifold with new seals. Fit and tighten nine external Torx screws (E12, M8 x 27) from the inside out.
-> 261019 Removing and installing exhaust manifold - Turbo Service and Repair.
=> Initial tightening: 12 Nm (9 ftlb.)
=> Final tightening: 30 Nm (22 ftlb.)
16. Fit turbocharger holder using two external Torx screws (E12, M8 x 35) -2-.
=> Tightening torque: 23 Nm (17 ftlb.)





Holder for turbocharger and bar ignition modules

17. Install coolant distributor -1-. Coat new O-rings with Kluber Gel.
17.1. Fit coolant distributor into coolant pipes.
17.2. Fit spring band clamps -3- on coolant hoses.
17.3. Fit coolant distributor using two external Torx screws (E10, M6 x 25) -4- and tighten screws.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Coolant distributor

18. Fit coolant run-on pump -1-.
18.1. Insert coolant pump and connect coolant hoses.
18.2. Close spring band clamps -2 and 3-.
18.3. Fit cable plugs -2- when installing the wire harness.





Coolant run-on pump (turbocharger cooling)

19. Fit transport eyebolt.
19.1. Fit and tighten two external Torx screws (E10, M6 x 25).
=> Tightening torque: 13 Nm (9.5 ftlb.)
20. Install knock sensors (observe installation position and position of connectors).
-> 287219 Removing and installing knock sensor - Turbo.
20.1. Fit and secure sensors using one external Torx screw (E12, M8 x 35) on each sensor.
=> Tightening torque: 23 Nm (17 ftlb.)
21. Fit fuel collection pipes -2- and injectors.
-> 243019 Removing and installing fuel collection pipe with fuel injectors.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Screws on fuel collection pipe

22. Install the starter.
-> 276019 Removing and installing starter Service and Repair.
23. Install bracket for oil/water heat exchanger -1- with new O-rings.
Fit and tighten seven external Torx screws (E10): five M6 x 45 screws -2- and two M6 x 60 screws -3-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
23.1. Pull out stoppers and fit and grease new O-rings -4-.





Bracket for oil/water heat exchanger

24. Install oil/water heat exchanger -1-.
-> 174019 Removing and installing oil/water heat exchanger 174019 Removing and installing oil/water heat exchanger.
Fit and tighten six internal Torx screws (T30) M6 x 20 -2-.
=> Contact force: 13 Nm (9.5 ftlb.)





Oil/water heat exchanger

25. Install oil separator -3- with new O-rings.
25.1. Grease O-rings, fit oil separator and secure with two external Torx screws (E10, M6 x 25) -4-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
25.2. Clip in B+ line -2- and connect vent line -1-.





Oil separator with B+ line

26. Install secondary-air lines with valves.
26.1. Route lines and fit and tighten external Torx screws.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Secondary-air lines

27. Install hydraulic pump with reservoir.
-> 489819 Removing and installing hydraulic pump - PDK and manual transmission Service and Repair.
28. Install air-conditioning compressor.
-> 873419 Removing and installing air-conditioning compressor 873419 Removing and installing air-conditioning compressor.
29. Install B+ wire harness (engine).
-> 974519 Removing and installing wire harness for battery wiring 974519 Removing and installing wire harness for battery wiring.
30. Fit and connect engine wire harness.
-> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine.
30.1. Secure cable duct to cylinder head 1-3 and 4-6 using one external Torx screw (E12, M8 x 16) on each.
=> Tightening torque: 23 Nm (17 ftlb.)
31. Fit fuel connection line (high-pressure side) to fuel collection pipe.
-> 243019 Removing and installing fuel collection pipe with fuel injectors.
31.1. Grease thread with OKS 1700 lubricant and tighten threaded connections -1 to 5- according to tightening sequence.
=> Tightening torque: 20 Nm (15 ftlb.)
=> Tightening torque: 13 Nm (9.5 ftlb.)





Tightening sequence for connecting line

32. Fit coolant hoses -2- to oil/water heat exchangers.
32.1. Coat hoses with Kluber Gel and fit them. Close two spring band clamps -1-.





Coolant hoses on heat exchanger

33. Fit electric control valve -1- and vacuum lines -3-.





Electric control valve with vacuum lines

34. Route vacuum line -1- and oil-level sender cable -2- , clip them in -arrows- and connect them -4-.





Vacuum line for brake booster and oil-level sender cable

35. Install the generator.
-> 272219 Removing and installing generator Service and Repair.
36. Install oil filler neck -1-.
36.1. Grease new O-ring and fit oil filler neck on crankcase.
36.2. Tighten two external Torx screws (E10, M6 x 20) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Oil filler neck

37. Install positive crankcase ventilation line -1-.
37.1. Grease two new O-rings and fit line to bracket for oil/water heat exchanger. Tighten external Torx screw (E10, M6 x 20) -2-.
37.2. Clip in line at two places and fit rapid-action couplings on cylinders 1-3, cylinders 4-6 and on the oil filler neck -3-.





Positive crankcase ventilation line

38. Route coolant vent line from the coolant distributor to the belt side via the fuel connection line and crankcase vent line.
39. Fit heat shields -2-.
39.1. Fit and tighten two external Torx screws (E10, M6 x 12) -3- on each.
=> Tightening torque: 10 Nm (7.5 ftlb.)





Heat shield (view of cylinder bank 1-3)

40. Install turbocharger with wire assembly.
-> 213019 Removing and installing turbocharger.
41. Fit coolant and oil lines (new O-rings) to the turbocharger.
41.1. Coolant lines and oil line on cylinder bank 4-6: Fit and tighten three M6 external Torx screws (E10) -1 to 3-.





Coolant lines and oil line on cylinder bank 4-6





41.2. Secure the oil pressure line -1- to the holder by fitting and tightening the external Torx screw (E10, M6 x 12) -2-.





Holder for oil pressure line on cylinder bank 4-6

41.3. Fit oil pressure line for cylinder bank 1-3 using a new O-ring on the cylinder head. Fit and tighten one external Torx screw (E10, M6 x 12).
41.4. Fit coolant lines -1- and oil line -3- on cylinder bank 1-3: Connect lines, close spring band clamps -2- and fit and tighten two M6 external Torx screws (E10) -4 and 5-.





Coolant and oil lines on cylinder bank 1-3

41.5. => Tightening torque: 10 Nm (7.5 ftlb.)
42. Install oil return lines and exhaust temperature sensor.
-> 217819 Removing and installing oil return line for turbocharger.
-> 216420 Removing and installing exhaust temperature sensors.
43. Install intake-air distributor.
-> 244619 Removing and installing intake-air distributor - turbo engine Service and Repair.
43.1. Fit complete intake-air distributor and position it on the cylinder heads.
43.2. Fit six external Torx screws (E10, M6 x 35) on each and tighten according to the specified tightening sequence.
=> Tightening torque: 13 Nm (9.5 ftlb.)
44. Fit intake air lines -1- and grease new O-rings with Kluber Syntheso Glep.
44.1. Cylinder bank 1-3:
44.1.1. Connect intake air line to the rubber mounting and turbocharger connection piece and fit cover on electronic adjuster.
44.1.2. Fit and tighten two external Torx screws (E10, M6 x 30) on the turbocharger and cover.
=> Tightening torque: 10 Nm (7.5 ftlb.)
44.1.3. Fit hose connections on the ambient air valve -2 and 3- and clip in the hose -arrow-.





Intake air line on cylinder bank 1-3

44.2. Cylinder bank 4-6:
44.2.1. Connect intake air line to the rubber mounting and turbocharger connection piece.
44.2.2. Fit and tighten two external Torx screws (E10, M6 x 20) on the turbocharger.
Tightening torque: 10 Nm (7.5 ftlb.)
44.2.3. Connect positive crankcase ventilation line -4- , fit hose connections on the ambient air valve -2 and 3- and clip in the hose -left arrow-.





Intake air line on cylinder bank 4-6

45. Install secondary-air pump -1-.
-> 266519 Removing and installing secondary-air pump - Turbo.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Secondary-air pump on cylinder bank 1-3

46. Fit tank vent valve on holder for intake-air distributor 1-3 and attach rapid-action coupling.
46.1. Plug in cable plugs on intake-air distributor for cylinder bank 1-3. Tighten one external Torx screw (E10, M6 x 12) used to secure the cable duct.
=> Tightening torque: 13 Nm (9.5 ftlb.)
47. Fit oil filler neck to holder.
47.1. Tighten three external Torx screws (E10, M6 x 12) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)





Holder for oil filler tube and positive crankcase ventilation line

48. Fit hydraulic pump pulley -1- using three external Torx screws (E12, M8 x 12) -2-.





Hydraulic pump pulley

49. Install the drive belt.
-> 137819 Removing and installing drive belt - Turbo Service and Repair.
50. Tighten external Torx screws on hydraulic pump pulley.
=> Tightening torque: 23 Nm (17 ftlb.)
51. Fit engine carrier -1- and holder for front silencer -5-.
-> 103019 Removing and installing engine carrier 103019 Removing And Installing Engine Carrier - Turbo.





Engine carrier and holder for front silencer

52. Fit rear silencer.
-> 263319 Removing and installing rear silencer Service and Repair.
53. Fit front silencer.
-> 262519 Removing and installing front silencer.
54. Remove the engine from the engine assembly support.
-> 1001IN Tools for removing units and working on the engine assembly support Tools and Equipment.
55. Fit flywheel with new screws.
-> 136019 Removing and installing flywheel - PDK transmission 136019 Removing and installing flywheel.
-> 136019 Removing and installing dual-mass flywheel 136019 Removing And Installing Dual-mass Flywheel - Turbo.
56. Mount the transmission.
-> 34352750 Removing and mounting transmission 34352750 Removing and mounting transmission.
-> 373427 Removing and mounting Porsche Double Clutch (PDK) 373427 Removing and mounting Porsche Doppelkupplung (PDK).
57. Install the engine.
-> 100119 Removing and installing engine 100119 Removing and installing engine.