Part 3

Assembling V8 4.8-liter DFI engine as of October 2008 (Continued)

Adjusting preload

53. Set dial gauge scale to 0. To do this, place the dial gauge holder on a completely flat surface (e.g. crankcase) and turn the dial gauge scale until the pointer is at 0.

Setting dial gauge scale to zero

54. Measure offset. In order to do this, push with the holder starting from the lower part of the crankcase towards the timing-case cover (the foot of the dial gauge holder is not located on the same component as the dial gauge probe) and measure the offset. The timing-case cover must not be set back any more than 0.1 mm. A projection is not permissible.

Measuring offset

55. Align the timing-case covers by tapping lightly with a rubber hammer.

Aligning chain case lid

56. Then check the position of the timing-case cover again with the dial gauge.

Checking

57. Fit timing-case cover according to specifications. When doing so, do not forget any of the sheetmetal holders under the screws.

Tightening sequence for timing-case cover

A - Aluminum screw, M6 x 30; timing-case cover to crankcase and cylinder head; always use new aluminum screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

B - Aluminum screw, M6 x 55; inner timing-case cover to upper part of crankcase and cylinder head; always use new aluminum screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°; outer timing-case cover to cylinder head - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

C - Aluminum screw, M8 x 55; timing-case cover (chain tensioner position) to upper part of crankcase and cylinder head; always use new aluminum screws; - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90°

D - The timing-case cover must be level with the lower part of the crankcase (use a steel rule or dial gauge)

58. Fit new joint flange between the vibration damper and timing-case cover. Align joint flange, fit screws and pull plastic sleeve.

Seal with plastic sleeve

Chain tensioner, joint flange

1 - Joint flange (oil sealing lip with engine oil); align with sleeve or vibration balancer

2 - Aluminum screw M6 x 20; always use new aluminum screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

3 - Aluminum screw M6 x 55; always use new aluminum screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

4 - Sealing ring

5 - Chain tensioner - Tightening torque: 60 Nm (44 ftlb.)

59. Turn the engine around. Oil pump is upright.
60. Lay sealing ring in the lower part of the crankcase.
61. Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.

Applying sealant to oil guide housing

1 - Seal application (geometry, 1-mm bead of sealant)

2 - Sealant application - Doboseal 224N (999.915.573.43, status 09/08)

A - Direction of travel

62. Position oil guide housing and align against transmission or projection of lower part of the crankcase. On the transmission side the oil guide housing must not project further than the crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil guide housing can be adjusted in the same way as the timing-case cover (using a dial gauge, etc.).
63. Screw down oil guide housing. Tighten all screws evenly crosswise. see item 6 Do not forget screws between the oil guide housing and timing-case cover (four screws behind front vibration balancer, bores are currently overhead).

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 - Timing-case cover to oil guide housing Aluminum screw; always use new aluminum screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°; oil-level sensor to oil guide housing (steel screw) - Tightening torque: 12 Nm (9 ftlb.); oil guide housing to lower part of crankcase, aluminum screw; always use new aluminum screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

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

64. Equip intake manifold oil strainer with sealing ring and then fit it. Tighten all oil pipes. Replace sealing rings.

Oil lines on naturally aspirated engine (M48/01)

1 - Intake pipe on oil pump

2 - O-ring

3 - Oil pressure pipe

4 - O-ring

5 - O-ring

6 - Oil regulating line

7 - O-ring

8 - O-ring

9 - Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing - Tightening torque: 12 Nm (9 ftlb.); oil control line to oil pump and oil guide housing - Tightening torque: 12 Nm (9 ftlb.)

10 - Screw, M6 x 20 - Tightening torque: 12 Nm (9 ftlb.)

Oil lines, intake pipe on naturally aspirated engine M48/01

1 - Mount for oil pump intake manifold

2 - Mount for oil separator vent line, cylinders 5 to 8

3 - Mount for oil pressure pipe

4 - Mount for oil regulating line

65. Push joint flange of the oil pressure control valve through the side oil pan opening via the oil pressure control valve and secure using two screws. Item 10 Fit oil level sensor (turn carefully when inserting) item 7

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 - Timing-case cover to oil guide housing Aluminum screw; always use new aluminum screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°; oil-level sensor to oil guide housing (steel screw) - Tightening torque: 12 Nm (9 ftlb.); oil guide housing to lower part of crankcase, aluminum screw; always use new aluminum screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

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

66. Fit lower oil pan and tighten evenly crosswise (the inserted seal can be reused provided it does not leak and is not damaged). Insert and fit oil drain plug with new sealing ring.

Oil pan

1 - Oil pan with reusable seal inserted

2 - Sealing ring

3 - Oil drain plug, M18 x 1.5 - Tightening torque: 50 Nm (37 ftlb.)

4 - Screw, M6 x 20 - Tightening torque: 10 Nm (7.5 ftlb.)

A - Direction of travel

67. Turn the engine around.
68. Position vibration balancer with screw tightened by hand.
69. Set the timing. Follow procedure exactly.
70. Fit small sideline brackets for the ATF lines.

Warning
Risk of damage to the engine and danger of crushing if the engine tips over
When removing and installing the vibration balancer with the engine removed (engine on assembly support), excessive use of force can cause the assembly mounting to become kinked.

- The engine must be supported at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block. This applies to all engines and assembly mountings.

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° 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

Supporting engine (illustration shows V8 4.5-liter engine supported on assembly support)

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 - 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 - see relevant section

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 06/08). 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 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

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 - Cap

A - Direction of travel

80. Fit water pump.

Fit pulley for 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 - Aluminum screw, M8; always use new aluminum screws - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90°

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.)

2 - Hydraulic belt tensioner; tensioner to lever - Tightening torque: 32 Nm (24 ftlb.); tensioning roller to tensioning lever - Tightening torque: 32 Nm (24 ftlb.)

3 - Screw, M8 x 96; complete lever to timing-case cover and cylinder head - Tightening torque: 32 Nm (24 ftlb.); belt tensioner and timing-case cover to bracket - Tightening torque: 32 Nm (24 ftlb.)

4 - Deflection roller - Tightening torque: 32 Nm (24 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 crankshaft sealing ring on flywheel side.
93. Fit coolant hosing and secure clamps.

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 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

94. 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.
95. 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 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.).

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 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.).

96. 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 - Timing-case cover to oil guide housing Aluminum screw; always use new aluminum screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°; oil-level sensor to oil guide housing (steel screw) - Tightening torque: 12 Nm (9 ftlb.); oil guide housing to lower part of crankcase, aluminum screw; always use new aluminum screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

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

97. 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

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

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

Tightening sequence for exhaust manifold on naturally aspirated engine M48/01, cylinders 1 to 4

101. Lay cable for lambda sensors and clip into position.

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

102. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. Item 7

Oil mist separator for positive crankcase ventilation (M48/01 naturally aspirated engine)

1 - Engine ventilation - Tightening torque: 10 Nm (7.5 ftlb.)

2 - Engine ventilation line

3 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)

4 - Lid with seal

5 - Engine ventilation line

6 - Line

7 - Tank ventilation with holder - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90°

103. 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.
104. 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.
105. Fit power-steering pump.
106. Fit air conditioning compressor.
107. 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

108. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench).
109. Fit heat protection panels on generator and on exhaust manifold. - Tightening torque: 10 Nm (7.5 ftlb.).

Heat protection panels on V8 naturally aspirated engine

110. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.