Part 3
WM 1001Z2 Assembling engine
Vacuum pump
61. Fit spark plugs if necessary. -> 287020 Removing and fitting spark plugs Service and Repair
62. Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see -> 158219 Removing and installing cylinder head cover Service and Repair
63. Fit both eyelets.
64. Move thermostat housing between the two sides of the crankcase into installation position. Tighten three screws (leave one loose for the fuel rail). Grease sealing ring on the small coolant pipe sparingly with Kluber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be pre-fitted and installed complete with the rear coolant pipe.
Thermostat housing and coolant regulator
65. Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50:50 with water) and press them as far as they will go into the thermostat housing. For details, see -> 195819 Removing and installing coolant regulator (thermostat insert) 195819 Removing and installing coolant regulator (thermostat)
66. Grease both sealing rings on the coolant pipe sparingly with Kluber Syntheso GLEP 1 and press them into the thermostat housing from the rear. Align with screw points on the coolant collection pipe and then screw down!
Coolant guide
67. Fit the water pump. Fit pulley for water pump. For details, see -> 195019 Removing and installing coolant pump Service and Repair
68. Fit oil pressure sensor with adapter. Replace sealing rings.
Oil pressure sensor and oil pressure measuring point
69. Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor -1-.
Left bracket for auxiliary units and engine mounting
70. Fit bearing console on the right. -1-
Right bracket for auxiliary units and engine mounting
71. Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position. -> 103519 Removing and installing engine mounting Service and Repair
72. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
Coolant supply on naturally aspirated engine
73. Fit the generator and crash support. For details, see -> 272219 Removing and installing generator Service and Repair
Generator
74. Fit deflection rollers and belt tensioner and press on cover.
Belt drive
75. Fit crankshaft sealing ring on flywheel side. See -> 135919 Removing and installing sealing ring for crankshaft (transmission side) Service and Repair
76. Fit coolant hosing and secure clamps.
Coolant supply on naturally aspirated engine
Coolant return on naturally aspirated engine
77. Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.
Ventilation
78. Roughly position engine wire harness. Place cable duct onto coolant collection pipe and lay both harnesses for the cylinder banks. At the timing-case cover lay them downwards to the generator. Wire up air conditioning compressor, insert injectors, wire up bar ignition modules. Screw down ground points. For details, see -> 975219 Removing and installing wire harness for engine 975219 Removing and installing wire harness for engine
79. Fit high-pressure line and low-pressure line => High-pressure pump on naturally aspirated engine. To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.
High-pressure pump on naturally aspirated engine
80. Fit high-pressure fuel distribution pipe. For details, see -> 243019 Removing and installing fuel distribution pipe Service and Repair
81. Check the DFI high-pressure system for leaks. -> 243001 Checking fuel distribution pipe for leaks Testing and Inspection
82. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
Exhaust manifold on naturally aspirated engine (cylinders 1 to 4 shown)
83. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. -3-
Ventilation on naturally aspirated engines
84. Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see -> 244619 Removing and installing intake-air distributor Service and Repair
85. Fit oil mist separator. For details, see -> 105519 Removing and installing oil mist separator Service and Repair.
86. Fit power-steering pump. For details, see installation description -> 489855 Replacing hydraulic pump Service and Repair
87. Fit air conditioning compressor. -> 873419 Removing and installing air conditioning compressor Service and Repair
88. Fit pulley for power-steering pump or tandem pump.
Pulleys
89. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). -> 137819 Removing and installing drive belt Service and Repair
90. Fit heat protection panels on generator and on exhaust manifold.
Heat protection panels on V8 naturally aspirated engine
91. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.