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. Lay boost-pressure control and circulating air lines at the engine and clip in.
Boost pressure and wastegate
Boost pressure and wastegate 2
67. 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
68. Fit the water pump. Fit pulley for water pump. For details, see -> 195019 Removing and installing coolant pump Service and Repair
69. Fit oil pressure sensor with adapter. Replace sealing rings.
Oil pressure sensor and oil pressure measuring point
70. Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC). Fit auxiliary unit bracket for right engine mounting.
Left bracket for auxiliary units and engine mounting
Right bracket for auxiliary units and engine mounting
71. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
Coolant supply on turbo engine
72. Fit the generator and crash support. For details, see -> 272219 Removing and installing generator Service and Repair
Generator
73. Fit deflection rollers and belt tensioner and press on cover.
Belt drive
74. Fit crankshaft sealing ring on flywheel side. See -> 135919 Removing and installing sealing ring for crankshaft (transmission side) Service and Repair
75. Fit coolant hosing and secure clamps.
Coolant return on turbo engine
Coolant supply on turbo engine
76. 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
77. If you have not already done so, secure sheetmetal holder of tank vent to the second upper screw of the timing-case cover at the 1st cylinder.
78. Fit PCV lines.
Positive crankcase ventilation (PCV) on turbo engine
79. 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
80. Fit high-pressure line between the high-pressure pump and fuel distribution pipe item 2. To do this, fit union nut in cylinder head item 4. Clip in cable duct at the union nut.
High-pressure pump, turbo engine
81. Fit high-pressure fuel distribution pipe. For details, see -> 243019 Removing and installing fuel distribution pipe Service and Repair
82. Check the DFI high-pressure system for leaks. -> 243001 Checking fuel distribution pipe for leaks Testing and Inspection
83. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
Tightening sequence for exhaust manifold on turbo engine, cylinders 1 to 4
Exhaust manifold on turbo engine, cylinders 1 to 4
Exhaust manifold on turbo engine, cylinders 5 to 8
84. Pre-fit the coolant and oil circuit lines, which are hard to reach when fitted, on the turbocharger.
Turbocharger, cylinders 1 to 4 - cooling
Turbocharger, cylinders 5 to 8 - cooling
Oil circuit for turbocharger, cylinders 1 to 4
Oil circuit for turbocharger, cylinders 5 to 8
85. Fit the turbocharger. Fit seals correctly. Observe tightening sequence. It is best to fit the turbocharger to the engine with the lines connected and fitted and then screw it on.
86. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. => Ventilation on turbo engines
Ventilation on turbo engines
87. 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 Overhaul
88. Fit oil mist separator. For details, see -> 105519 Removing and installing oil mist separator Service and Repair.
89. Fit power-steering pump. For details, see installation description -> 489855 Replacing hydraulic pump Service and Repair
90. Fit air conditioning compressor. -> 873419 Removing and installing air conditioning compressor Service and Repair
91. Fit pulley for power-steering pump or tandem pump.
Pulleys
92. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). -> 137819 Removing and installing drive belt Service and Repair
93. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.