Part 3
WM 1001IN Tightening torques, tightening sequences, assembly overviews for V8 4.8 liter DFI naturally aspirated and turbo engines (continued)Group 19
Coolant pump
1 - Coolant pump
2 - Seal; fitted in pump
3 - Screw, M6 x 25 - For details of tightening sequence, see below - Tightening torque: 10 Nm (7.5 ftlb.)
A - Direction of travel
Tightening sequence for coolant pump
Coolant guide
1 - Coolant pipe with sealing ring
2 - Coolant sensor - Tightening torque: 30 Nm (22 ftlb.)
3 - Screw, M6 x 16 - Tightening torque: 12 Nm (9 ftlb.)
4 - Screw M6 x 12 (currently not installed)
5 - Holding clamp (currently not installed)
6 - Sealing ring
7 - Screw plug, M16 x 1.5 - Tightening torque: 30 Nm (22 ftlb.)
8 - Screw, M6 x 25 - Tightening torque: 12 Nm (9 ftlb.)
9 - Collection pipe
10 - Distributor pipe seal
11 - Lid
A - Direction of travel
Thermostat housing
1 - Thermostat housing
2 - Screw, M6 x 25 - Tightening torque: 10 Nm (7.5 ftlb.)
3 - Screw, M6 x 25; screwed to fuel high-pressure distribution pipe
4 - Seal for thermostat housing; replace
5 - Thermostat
6 - Intake socket
A - Direction of travel
Tightening sequence for thermostat housing
Coolant return line on turbo engine M48/51
1 - Coolant pipe
2 - Coolant hose
3 - Holder
4 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
5 - Screw, M6 x 20 - Tightening torque: 10 Nm (7.5 ftlb.)
6 - Connect tab on oil/coolant heat exchanger
B - Clip on to support bracket
A - Direction of travel
Coolant return line on naturally aspirated engine M48/01
1 - Coolant pipe
2 - Coolant hose
3 - Holder
4 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
5 - Screw, M6 x 20 - Tightening torque: 10 Nm (7.5 ftlb.)
Coolant supply line on turbo engine M48/51
1 - Coolant pipe
2 - Screw, M6 x 12; coolant line to collection pipe and right engine carrier - Tightening torque: 10 Nm (7.5 ftlb.); coolant supply line to right oil feed line - Tightening torque: 10 Nm (7.5 ftlb.); coolant supply line to right turbocharger coolant line - Tightening torque: 10 Nm (7.5 ftlb.)
3 - Clip
4 - Coolant supply hose for oil/coolant heat exchanger
5 - Coolant supply hose
6 - Adapter for coolant supply line for turbocharger, cylinders 1 to 4
A - Direction of travel
Coolant supply line on naturally aspirated engine M48/01
1 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Coolant pipe
3 - Coolant supply hose
4 - Coolant hose
Ventilation
1 - Vent line
2 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Direction of travel
Group 24
Fuel distribution pipe
1 - Fuel gallery
2 - Stopper; in 3 turns (tighten, loosen, tighten) - Tightening torque: 25 Nm (19 ftlb.)+2.5 Nm (+2.0 ftlb.)-3.7 Nm (-3.0 ftlb.)
3 - High-pressure sensor - Tightening torque: 20 Nm (15 ftlb.)±2 Nm (±1.5 ftlb.)
Injectors (high-pressure fuel injectors)
1 - Holder
2 - Screw, M8 x 30 - Tightening torque: 23 Nm (17 ftlb.)
3 - Injector (high-pressure fuel injector)
Mount for fuel distribution pipe
1 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Screw, M6 x 25 - Tightening torque: 10 Nm (7.5 ftlb.)
3 - High-pressure line connection
4 - Connection to injector (high-pressure fuel injector); in 3 turns (tighten, loosen, tighten) - Tightening torque: 25 Nm (19 ftlb.)+2.5 Nm (+2.0 ftlb.)-3.7 Nm (-3.0 ftlb.)
High-pressure pump on turbo engine M48/51, 6-piston pump
1 - High-pressure pump
2 - High-pressure line; (3 turns: tighten, loosen, tighten) - Tightening torque: 25 Nm (19 ftlb.)+2.5 Nm (+2.0 ftlb.)-3.7 Nm (-3.0 ftlb.)
3 - Low-pressure line; (3 turns: tighten, loosen, tighten) - Tightening torque: 25 Nm (19 ftlb.)+2.5 Nm (+2.0 ftlb.)-3.7 Nm (-3.0 ftlb.)
4 - Screw socket, M8 - Tightening torque: 23 Nm (17 ftlb.)
5 - Screw socket, M6 - Tightening torque: 10 Nm (7.5 ftlb.)
6 - Protective plate
7 - Screw, M6 x 20 - Tightening torque: 10 Nm (7.5 ftlb.)
8 - Screw, M6 x 25 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Required line distance (5 to 8 mm) between high-pressure line and low-pressure line
- Temperature sensor; not shown, to low-pressure line - Tightening torque: 20 Nm (15 ftlb.)±2 Nm (± 1.5 ftlb.)
High-pressure pump on naturally aspirated engine M48/01, 3-piston pump
1 - High-pressure pump
2 - High-pressure line; (3 turns: tighten, loosen, tighten) - Tightening torque: 25 Nm (19 ftlb.)+2.5 Nm (+2.0 ftlb.)-3.7 Nm (-3.0 ftlb.)
3 - Low-pressure line; (3 turns: tighten, loosen, tighten) - Tightening torque: 25 Nm (19 ftlb.)+2.5 Nm (+2.0 ftlb.)-3.7 Nm (-3.0 ftlb.)
4 - Screw socket, M8 - Tightening torque: 23 Nm (17 ftlb.)
5 - Screw socket, M6 - Tightening torque: 10 Nm (7.5 ftlb.)
6 - Protective plate
7 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
8 - Screw, M6 x 25 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Required line distance (5 to 8 mm) between high-pressure line and low-pressure line
- Temperature sensor; not shown, to low-pressure line - Tightening torque: 20 Nm (15 ftlb.)±2 Nm (± 1.5 ftlb.)
Lambda sensor on naturally aspirated engine M48/01, cylinders 1 to 4
1 - Lambda sensor on primary catalytic converter - Tightening torque: 45 Nm (33 ftlb.)±5 Nm (± 3.5 ftlb.)
2 - Cable attachment
3 - Holder
4 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
5 - Cable attachment
A - View A
B - View B
Lambda sensor on naturally aspirated engine M48/01, cylinders 5 to 8
1 - Lambda sensor on primary catalytic converter - Tightening torque: 45 Nm (33 ftlb.)±5 Nm (± 3.5 ftlb.)
2 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
3 - Holder
4 - Holder
5 - Holder
6 - Cable attachment
7 - Cable attachment
A - View A
Tightening sequence for intake module (shown on M48/01) valid for M48/01 and M48/51
Intake module on naturally aspirated engine M48/01
1 - Intake module
2 - Decoupling module (fastening part); observe correct tightening sequence - Tightening torque: 15 Nm (11 ftlb.)±1.5 Nm (±1.0 ftlb.)
3 - Intake module seal; check that seal is aligned and fitted correctly!
4 - Heat socket
5 - Screw, M5 x 16 - Tightening torque: 2.2 Nm (1.5 ftlb.)±0.2 Nm (±0.1 ftlb.)
6 - Screw, M6 x 50 - Tightening torque: 8 Nm (6 ftlb.)±0.8 Nm (±0.5 ftlb.)
7 - Electronic accelerator
8 - Seal
9 - Ball socket
Variable intake manifold actuator on naturally aspirated engine M48/01
1 - Pipe
2 - Connecting piece
3 - Variable intake manifold adjuster/adjusting unit
4 - Lip seal
5 - Connecting element
6 - Vacuum unit with cover (actuator)
7 - Screw, M5 x 16 - Tightening torque: 4 Nm (3 ftlb.)
8 - Driver
9 - Connecting rod
10 - Vacuum line
Intake air module on turbo engine M48/51
1 - Intake module
2 - Decoupling module (fastening part); observe correct tightening sequence - Tightening torque: 15 Nm (11 ftlb.)±1.5 Nm (±1.0 ftlb.)
3 - Intake module seal; check that seal is aligned and fitted correctly!
4 - Heat socket
5 - Screw, M5 x 16 - Tightening torque: 2.2 Nm (1.5 ftlb.)±0.2 Nm (±0.1 ftlb.)
6 - Screw, M6 x 50 - Tightening torque: 8 Nm (6 ftlb.)±0.8 Nm (±0.5 ftlb.)
7 - Electronic accelerator
8 - Seal
9 - Ball socket
Group 26
Tightening sequence for exhaust manifold on naturally aspirated engine M48/01, cylinders 1 to 4
Tightening sequence for exhaust manifold on turbo engine M48/51, cylinders 1 to 4
Exhaust manifold on turbo engine M48/51, cylinders 1 to 4
1 - Exhaust manifold
2 - Exhaust manifold seal
3 - Exhaust turbocharger seal
4 - Screw, M8 x 75 - Initial tightening: 23 Nm (17 ftlb.) - Final tightening: 30 Nm (22 ftlb.)
5 - Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence - Tightening torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
A - Marking on seal visible from outside
Exhaust manifold on turbo engine M48/51, cylinders 5 to 8
1 - Exhaust manifold
2 - Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence - Tightening torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
3 - Screw, M8 x 75 - Initial tightening: 23 Nm (17 ftlb.) - Final tightening: 30 Nm (22 ftlb.)
4 - Exhaust turbocharger seal
5 - Exhaust manifold seal
A - Marking on seal visible from outside
Exhaust manifold on naturally aspirated engine M48/01, cylinders 1 to 4
1 - Exhaust manifold
2 - Exhaust manifold seal
3 - Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence - Tightening torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
4 - Lambda sensor - Tightening torque: 45 Nm (33 ftlb.)±5 Nm (±3.5 ftlb.)
A - Marking on seal visible from outside
Exhaust manifold on naturally aspirated engine M48/01, cylinders 5 to 8
1 - Exhaust manifold
2 - Seal
3 - Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence - Tightening torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
4 - Lambda sensor - Tightening torque: 45 Nm (33 ftlb.)±5 Nm (±3.5 ftlb.)
A - Marking on seal visible from outside
Group 27
Engine wire harness, inner V
1 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
Engine wire harness, timing case and valve cover
1 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
Engine wire harness, generator
1 - Holder
G - Cable clips
Wire harness assignment
1 - Bar ignition module, cylinder 1
2 - Bar ignition module, cylinder 2
3 - Bar ignition module, cylinder 3
4 - Bar ignition module, cylinder 4
5 - Bar ignition module, cylinder 5
6 - Bar ignition module, cylinder 6
7 - Bar ignition module, cylinder 7
8 - Bar ignition module, cylinder 8
9 - Injector, cylinder 1
10 - Injector, cylinder 2
11 - Injector, cylinder 3
12 - Injector, cylinder 4
13 - Injector, cylinder 5
14 - Injector, cylinder 6
15 - Injector, cylinder 7
16 - Injector, cylinder 8
17 - Camshaft adjuster
18 - Camshaft adjuster
19 - Hydraulic valve for variable valve lift control
20 - Knock sensor
21 - Engine ground for camshaft adjuster
22 - Engine ground for camshaft adjuster
23 - Engine ground for camshaft adjuster
24 - Engine ground for camshaft adjuster
25 - Speed sensor
26 - Hall sender (phase sensor)
27 - Hall sender (phase sensor)
28 - Knock sensor
29 - Knock sensor
30 - Knock sensor
31 - Knock sensor
32 - Tank vent
33 - Generator
34 - Crankcase heating
35 - Flow control valve
36 - Oil pressure regulating valve
37 - Water temperature sensor
38 - Air conditioning compressor
39 - Oil-level sensor
40 - Oil-pressure sender with oil temperature sensor
41 - Electronic accelerator
42 - High-pressure sensor
43 - Starter, terminal 50
44 - Starter, terminal 30
45 - Starter, terminal 30
46 - Generator, B+
47 - Transfer point on vehicle, B+
48 - Intake manifold switch-over valve
49 - Vehicle/engine connection point
50 - Vehicle/engine connection point
51 - Direct Fuel Injection (DFI) control unit
52 - Body ground
53 - Clutch protection connection point
54 - Dummy plug for clutch protection
55 - Boost pressure sensor (Turbo)
56 - Boost pressure cycle valve (Turbo)
57 - Wastegate change-over valve (Turbo)
A - Direction of travel
Wire harness for starter
1 - Nut, M8 - Tightening torque: 18 Nm (13 ftlb.)
2 - Nut, M6 - Tightening torque: 8.5 Nm (6.5 ftlb.)
Wire harness for generator
1 - Cap nut, M8 - Tightening torque: 18 Nm (13 ftlb.)
2 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
3 - Heat shield
Generator
1 - Generator
2 - Screw, M8 x 95 - Tightening torque: 23 Nm (17 ftlb.)
3 - Screw, M8 x 35 - Tightening torque: 23 Nm (17 ftlb.)
4 - Bores for screws, M8 x 95
A - View
Starter
1 - Starter
2 - Screw, M10 x 45 - Tightening torque: 45 Nm (33 ftlb.)+8 Nm (+6 ftlb.)
Group 28
Knock sensors
1 - Knock sensor
2 - Screw, M8 x 35 - Tightening torque: 23 Nm (17 ftlb.)
Group 47
Vacuum pump
1 - Vacuum pump
2 - Screw, M6 x 25 - Tightening torque: 10 Nm (7.5 ftlb.)
3 - O-ring
4 - O-ring
Group 48
Auxiliary units
1 - Air conditioning compressor
2 - Screw, M10 x 100
3 - Screw, M8 x 10
4 - Holder
5 - Screw, M8 x 20; tandem pump to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.); power-steering pump to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.)
6 - Tandem pump
7 - Screw, M8 x 35; power-steering pump to adapter bracket - Tightening torque: 23 Nm (17 ftlb.); tandem pump/adapter bracket to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.)
8 - Power-steering pump
9 - Screw, M8 x 35 - Tightening torque: 23 Nm (17 ftlb.)
10 - Support bracket
11 - Dowel sleeve
Pulleys
1 - Water pump pulley
2 - Screw, M8 x 16 - Tightening torque: 23 Nm (17 ftlb.)
3 - Vibration damper
4 - Screw, M18 x 1.5 x 72; use new screw; - Tightening torque: 20 Nm (15 ftlb.) - Tightening torque: 50 Nm (37 ftlb.) - Tightening torque: 100 Nm (74 ftlb.) - Torque angle: 180°
5 - Pulley on power-steering pump
6 - Screw, M8 x 16 - Tightening torque: 23 Nm (17 ftlb.)
7 - Tandem pump pulley
Group 87
Auxiliary units
1 - Air conditioning compressor
2 - Screw, M10 x 100 - Tightening torque: 46 Nm (34 ftlb.)
3 - Screw, M8 x 100 - Tightening torque: 23 Nm (17 ftlb.)
4 - Holder
5 - Screw, M8 x 20
6 - Tandem pump
7 - Screw, M8 x 35
8 - Power-steering pump
9 - Screw, M8 x 35
10 - Support bracket
11 - Dowel sleeve