Part 3

Assembling V8 4.8-liter DFI engine up to October 2008 (Continued)

71. Tighten vibration balancer to the specified torque (use brace brace 9679/1). Make a mark between the screw and the vibration balancer using a water-resistant marker (continuous line from screw to vibration balancer). Mark a second line on the vibration balancer at 180 degrees from the first marking. Tighten from first marking to the second marking (torque-angle tightening). For exact tightening specification, see legend for figure Pulleys - item 4

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 degrees
5 - Power-steering pump pulley
6 - Screw, M8 x 16 - Tightening torque: 23 Nm (17 ftlb.)
7 - Tandem pump pulley

72. Fit high-pressure pump at cylinder head for cylinders 5 to 8.
73. Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.

Vacuum pump

1 - Vacuum pump
2 - Screw, M6 x 25 - Tightening torque: 10 Nm (7.5 ftlb.)
3 - O-ring
4 - O-ring

74. Fit spark plugs if necessary.
75. Fit both cylinder head covers (valve covers). Center cylinder head cover over the bar ignition modules.
76. Fit both eyelets.
77. 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.

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

Information
000 043 204 68 (Status 02/07) "Kluber Syntheso GLEP 1" is a neutral-reaction assembly grease that can be used for connection pieces and sealing rings in oily or water-carrying areas.
Use "Kluber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks.
"Kluberplus S06-100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06108). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.

78. Grease sealing rings at the intake socket between the water pump and 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.
79. Grease both sealing rings for the coolant pipe sparingly with Kluber Syntheso GLEP 1 and insert them into the thermostat housing from the rear. Align with screw points on the coolant collection pipe and then screw down!

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

80. Fit water pump.
81. Fit oil pressure sensor with adapter. Replace sealing rings.

Oil pressure sensor and oil pressure measuring point

1 - Oil-pressure sensor adapter
2 - O-ring
3 - Oil-pressure sender with temperature sensor
4 - Screw, M6 x 40 - Tightening torque: 10 Nm (7.5 ftlb.)
5 - Stopper - Tightening torque: 15 Nm (11 ftlb.)
6 - Sealing ring
A - Direction of travel

82. 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

1 - Bracket for auxiliary units/engine mounting
2 - Screw, M10 x 45 - Tightening torque: 65 Nm (48 ftlb.)
3 - Hydraulic mount, left
4 - Engine carrier
5 - Screw, M10 x 65 - Tightening torque: 60 Nm (44 ftlb.)
6 - Dowel sleeve
7 - Nut, M12 x 1.5 - Tightening torque: 75 Nm (56 ftlb.)

Right bracket for auxiliary units and engine mounting

1 - Engine carrier, cylinders 1 to 4
2 - Screw, M10 x 45 - Tightening torque: 65 Nm (48 ftlb.)
3 - Hydraulic mount, right
4 - Engine carrier
5 - Screw, M10 x 65 - Tightening torque: 60 Nm (44 ftlb.)
6 - Nut, M12 x 1.5 - Tightening torque: 75 Nm (56 ftlb.)
7 - Bores for screws, M10 x 45
A - Installation view of engine carrier on crankcase

83. Fit cable clips (sheet-metal clips to the unit brackets and valve covers.
84. Fit adapter plate for power-steering pump if necessary.

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

85. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.

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

86. Align both engine mountings (hydraulic mounts) and fit them in the brackets for auxiliary units. When doing so, briefly hold the engine carrier to align it with the engine mounting.

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

88. Position generator's crash support.
89. Screw down generator's crash support and generator.
90. Fit deflection rollers and belt tensioner and press on cover.

Belt drive

1 - Deflection roller - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
2 - Hydraulic belt tensioner; tensioner to lever - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.). tensioning roller to tensioning lever - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
3 - Screw, M8 x 96; complete lever to timing-case cover and cylinder head - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.). belt tensioner and timing-case cover to bracket - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
4 - Deflection roller - Tightening torque: 32 Nm (24 ftlb.)±3 Nm (±2 ftlb.)
5 - Dual poly V-belt

91. If you have not already done so, secure sheet metal holder of tank vent to the second upper screw of the timing-case cover at the 1st cylinder.
92. Fit PCV lines.

Positive crankcase ventilation (PCV), turbo engine M48/51

1 - Ventilation pipe with sealing ring - Tightening torque: 13 Nm (9.5 ftlb.)
2 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Installation view of ventilation pipe

93. Fit crankshaft sealing ring on flywheel side.
94. Fit coolant hosing and secure clamps.

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 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 - Clamp
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

95. 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.
96. Lay boost-pressure control and circulating air lines at the engine and clip in at the cable duct.

Boost pressure and wastegate

1 - Pressure line, boost pressure line
2 - Hose clamp
3 - Cycle valve
4 - Combination holder
5 - Holder - Tightening torque: 13 Nm (9.5 ftlb.)
6 - Control line
7 - Control line
8 - Hose holder

Boost pressure and wastegate 2

1 - Pressure line
2 - Vacuum line
3 - Hose clamp
4 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
5 - Holder
6 - Rubber element
7 - Electric change-over valve
8 - Control line
A - View A

97. 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 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.).
3 - Low-pressure line; (3 turns: tighten, loosen, tighten) - Tightening torque: 25 Nm (19 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.).

98. Fit oil dipstick tube item 1 (first grease sealing rings sparingly with Kluber Syntheso GLEP 1). Screw down on timing-case cover at the top.

Oil guide housing with accessories

1 - Guide tube
2 - O-ring
3 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.).
4 - Oil dipstick
5 - O-ring
6 - Screw, M6 x 25; timing-case cover to oil guide housing - Tightening torque: 12 Nm (9 ftlb.). oil level sensor to oil guide housing - Tightening torque: 10 Nm (9 ftlb.). oil guide housing to lower part of crankcase - Tightening torque: 13 Nm (9.5 ftlb.).
7 - Oil level sensor
8 - O-ring
9 - Joint flange
10 - Screw, M6 x 20 Tightening torque: 10 Nm (7.5 ftlb.).
11 - Screw, M6 x 16 Tightening torque: 10 Nm (7.5 ftlb.).
A - Direction of travel

99. Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Detach injector plug and fit coolant vent line into the clips at the rear under the cable duct if necessary. Screw down coolant vent line with seals at both cylinder heads.

Ventilation

1 - Vent line
2 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Direction of travel

100. Fit DFI high-pressure fuel distribution pipe.
101. Check the DFI high-pressure system for leaks.
102. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.

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 - 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 - Turbocharger seal
5 - Exhaust manifold seal
A - Marking on seal visible from outside

103. Pre-fit the coolant and oil circuit lines, which are hard to reach when fitted, on the turbocharger.

Turbocharger, cylinders 1 to 4 - cooling

1 - Coolant return line for turbocharger, cylinders 1 to 4
2 - Coolant supply line for turbocharger, cylinders 1 to 4
3 - Coolant supply hose for turbocharger, cylinders 1 to 4
4 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
5 - Clamp
6 - Hexagon nut, M6 - Tightening torque: 8.5 Nm (6.0 ftlb.)
7 - Banjo bolt, M12 x 1.25; coolant supply line to turbocharger - Tightening torque: 35 Nm (26 ftlb.). coolant return line to turbocharger - Tightening torque: 35 Nm (26 ftlb.)
8 - Connection for coolant supply hose for turbocharger, cylinders 1 to 4
9 - Connection for coolant return hose for turbocharger, cylinders 1 to 4
A - Direction of travel

Turbocharger, cylinders 5 to 8 - cooling

1 - Coolant supply line for turbocharger, cylinders 5 to 8
2 - Hexagon nut, M6 - Tightening torque: 8.5 Nm (6.0 ftlb.)
3 - Clamp
4 - Coolant return line for turbocharger, cylinders 5 to 8
5 - Banjo bolt, M12 x 1.25; coolant supply line to turbocharger - Tightening torque: 35 Nm (26 ftlb.). coolant return line to turbocharger - Tightening torque: 35 Nm (26 ftlb.)
6 - Collection pipe connection - Tightening torque: 35 Nm (26 ftlb.)
7 - Connection for coolant supply hose for turbocharger, cylinders 5 to 8
8 - Turbocharger, cylinders 5 to 8
A - Direction of travel

Oil circuit for turbocharger, cylinders 1 to 4

1 - Turbocharger vent line for cylinders 1 to 4; vent line to turbocharger oil extraction line - Tightening torque: 35 Nm (26 ftlb.). holding clamp on vent line to collection pipe, M6 screw - Tightening torque: 10 Nm (7.5 ftlb.). holding clamp on vent line to collection pipe, M6 nut - Tightening torque: 6.5 Nm (5.0 ftlb.)
2 - Turbocharger oil supply line for cylinders 1 to 4; turbocharger oil supply line to connection piece Tightening torque: 40 Nm (30 ftlb.). turbocharger oil supply line to cylinder head - Tightening torque: 35 Nm (26 ftlb.)
3 - Connection piece - Tightening torque: 45 Nm (33 ftlb.)
4 - Sealing ring
5 - Oil extraction line
6 - Screw, M6 x 12 Tightening torque: 10 Nm (7.5 ftlb.)
7 - Screw, M6 x 16 Tightening torque: 10 Nm (7.5 ftlb.)
8 - Seal for turbocharger, cylinders 1 to 4

Oil circuit for turbocharger, cylinders 5 to 8

1 - Oil supply line for turbocharger, cylinders 5 to 8
2 - Nut, M6 - Tightening torque: 6.5 Nm (5.0 ftlb.).
3 - Holding clamp
4 - Vent line on turbocharger for cylinders 5 to 8 - Tightening torque: 10 Nm (7.5 ftlb.).
5 - Holding clamp
6 - Screw, M6 x 12; turbocharger oil feed line holder to lower part of crankcase - Tightening torque: 10 Nm (7.5 ftlb.). holding clamp for oil feed line to holder - Tightening torque: 10 Nm (7.5 ftlb.).
7 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.).
8 - Oil extraction line
9 - Seal for turbocharger, cylinders 5 to 8
10 - Sealing ring
11 - Connection piece
12 - Clamp
13 - Holder for oil supply line

104. Fit turbocharger with the pre-fitted lines with seal to the exhaust manifold. Make sure that the fitted lines are located in the approximate installation position. Fit screws. Fit bracket between the cylinder head and the turbocharger and screw it down. (Tightening torques: refer also to "Exhaust manifold")

Turbocharger, cylinders 1 to 4

1 - Turbocharger, cylinders 1 to 4
2 - Hexagon nut, M8 - Tightening torque: 30 Nm (22 ftlb.).
3 - Screw, M8 x 20 - Tightening torque: 23 Nm (17 ftlb.).
4 - Turbocharger bracket
5 - Screw, M8 x 40 - Tightening torque: 30 Nm (22 ftlb.).
6 - Stud

Turbocharger, cylinders 5 to 8

1 - Turbocharger, cylinders 5 to 8
2 - Turbocharger bracket
3 - Screw, M8 x 20 Tightening torque: 23 Nm (17 ftlb.)
4 - Screw, M8 x 40 Tightening torque: 30 Nm (22 ftlb.)
5 - Hexagon nut, M8 - Tightening torque: 30 Nm (22 ftlb.)
6 - Stud

105. Fit oil extraction lines onto the turbocharger and the oil guide housing. Fit vent lines to the oil extraction line and then along the coolant collection pipe.
106. Screw the turbocharger lines to the cylinder head and the coolant collection pipe. Fit coolant hoses.
107. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheet metal brackets.

Oil mist separator for positive crankcase ventilation (M48/51 turbo engine)

1 - Engine ventilation - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Engine ventilation line
3 - Tank ventilation
4 - Holder - Tightening torque: 13 Nm (9.5 ftlb.)

108. Prepare and fit intake module. Ensure that the seals are seated correctly. Place intake module in installation position. Check that the switch-over valve is seated and connected properly.
109. Grease sealing rings for the two oil mist separators sparingly with Kluber Syntheso GLEP 1. Press oil mist separators onto the connection pieces on both valve covers. First fit the positive crankcase ventilation line between the timing-case cover and the oil mist separator at cylinder bank 5 to 8. Tighten screws and fit connecting tube between the oil mist separators.
110. Fit power-steering pump.
111. Fit air conditioning compressor.
112. Fit pulley for power-steering pump or tandem pump.

Pulleys

1 - Water pump pulley
2 - Screw, M8 x 16
3 - Vibration damper
4 - Screw, M18 x 1.5 x 72; use new screw;
5 - Power-steering pump pulley
6 - Screw, M8 x 16 - Tightening torque: 23 Nm (17 ftlb.).
7 - Tandem pump pulley

113. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench).
114. Fit heat protection panels on generator and on exhaust manifold. - Tightening torque: 10 Nm (7.5 ftlb.).
115. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.

Subsequent work

1. Fill in engine oil.
2. Remove engine from engine support.
3. Mount the engine on the transmission.
4. Install engine.