Part 5

WM 1001Z2 Assembling V8 4.8-litre DFI engine as of October 2008

100. Fit DFI high-pressure fuel distribution pipe. For details, see -> 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Installing" Service and Repair
101. Check the DFI high-pressure system for leaks. -> 243001 Checking fuel distribution pipe (fuel rail) on DFI engines for leaks 243001 Checking Fuel Distribution Pipe (Fuel Rail) on DFI Engines 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









Exhaust manifold on turbo engine M48/51, cylinders 5 to 8





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









Turbocharger, cylinders 5 to 8 - cooling









Oil circuit for turbocharger, cylinders 1 to 4









Oil circuit for turbocharger, cylinders 5 to 8





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









Turbocharger, cylinders 5 to 8





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 sheetmetal brackets.





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





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. For details, see -> 244619 Removing and installing intake-air distributor on DFI engines - section on "Installing" 244619 Removing and installing DFI intake-air distributor
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. For details, see -> 105519 Removing and installing oil mist separator on 4.8-litre DFI engines - section on "Installing" Service and Repair
110. Fit power-steering pump. -> 489819 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) - section on "Installing" 489819 Removing and installing hydraulic pump (PDCC)
111. Fit air conditioning compressor. -> 873419 Removing and installing air conditioning compressor - section on "Installing" Service and Repair
112. Fit pulley for power-steering pump or tandem pump.





Pulleys





113. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). -> 137819 Removing and installing drive belt on 4.8-litre DFI engines - section on "Installing" 137819 Removing and installing drive belt on 4.8 l DFI engine
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.