Part 2

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

23. Fit cross bolt connection.

Tightening sequence for securing lower part of crankcase to upper part of crankcase (cross bolt connection)

24. Fit M8 screws on the side -8 and 9-. Remove emerging sealant.
25. Punch in or imprint the engine number if necessary (when replacing engine).
26. Move oil plate with all the seals into installation position and secure to the lower part of the crankcase. - Tightening torque: 10 Nm (7.5 ftlb.)

Oil guide (oil plate)

27. Grease sealing ring between the oil plate transfer pipe and oil pump sparingly with Kluber Syntheso GLEP 1 and fit oil pump. Secure the oil pump.

Oil pump on turbo engine M48/51 with oil extraction stage

1 - Oil pump with extraction stage
2 - Screw, M8 x 22; replace; 1st turn - Initial tightening: 20 Nm (15 ftlb.) final tightening (torque angle) Torque angle: 90 degrees
3 - Oil pump sprocket
4 - Cap screw, M36 x 1.5 x 12 - Tightening torque: 40 Nm (30 ftlb.)
5 - Solenoid valve
6 - O-ring (grease before fitting)
7 - Dowel sleeve
8 - Screw, M6 x 45 Tightening torque: 13 Nm (9.5 ftlb.)
9 - Sprocket cover
10 - Screw, M6 x 16 Tightening torque: 10 Nm (7.5 ftlb.)
11 - Drive chain
12 - Connection for intake manifold joining socket
A - Direction of travel

28. Fit oil pump sprocket with drive chain with respect to the crankshaft chain pinion - Oil pump chain. Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw. 1st turn - Initial tightening: 20 Nm (15 ftlb.) final tightening (torque angle) - Torque angle: 90 degrees

Oil pump chain

Countering oil pump pinion

29. Fit cover plate for oil pump drive using three screws. - Tightening torque: 10 Nm (7.5 ftlb.)
30. Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both cylinder head seals. Part number/marking facing upward. When doing so, make sure that the cylinder head gasket is positioned on the dowel sleeves.
31. Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not already done so), as the bores in the cylinder head screws are covered. see illustration, item 8

Cylinder head 1 to 4

1 - Cylinder head 1 to 4
2 - Cylinder head gasket 1 to 4
3 - Screw, M8 - Tightening torque: 23 Nm (17 ftlb.)
4 - Cap
5 - Stopper
6 - Stopper
7 - Restrictor for valve lift control - Tightening torque: 1.5 Nm (1.0 ftlb.)
8 - Cylinder-head screws - For tightening specifications, see Tightening sequence for cylinder head
9 - Spark plug; when reinstalled - Tightening torque: 25 Nm (19 ftlb.)+3 Nm (+2 ftlb.); if fitting new spark plugs - Tightening torque: 30 Nm (22 ftlb.)+3 Nm (+2 ftlb.)

Tightening sequence for cylinder head

1 through 10 - 1st initial tightening - Tightening torque: 30 Nm (22 ftlb.); 2nd initial tightening - Tightening torque: 50 Nm (37 ftlb.) loosen by 2 turns - Torque angle: 720 degrees; 1st turn - Tightening torque: 30 Nm (22 ftlb.); 2nd turn - Tightening torque: 30 Nm (22 ftlb.); 3rd turn and final tightening (torque angle) - Torque angle: 110 degrees

33. Fit front M8 screw of cylinder head 1 to 4. - Tightening torque: 23 Nm (17 ftlb.)
34. Make sure that the intake openings have been protected using adhesive tape or something similar to prevent them from becoming dirty.
35. Insert front camshaft mounting saddles (lower parts) of cylinder heads. Item 8

Camshafts, cylinder bank 1 to 4

1 - Camshaft (outlet)
2 - Camshaft (intake)
3 - Hydraulic valve for variable valve lift control
4 - Screw, M5 x 12 - Tightening torque: 6 Nm (4.5 ftlb.)
5 - Switching tappet (oil with engine oil)
6 - Bucket tappet (oil with engine oil)
7 - Stopper
8 - Mounting saddle 1 to 4
9 - Stopper
10 - Bearing locations (oil with engine oil)
A - Direction of travel

36. Coat camshaft bearings with normal multipurpose grease or engine oil.
37. Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet side have different diameters). The bucket tappets have a twist lock that fits into a guide groove in the cylinder head. Fit used bucket tappets at the same position.
38. Position vibration balancer with screw tightened by hand. Turn crankshaft to just before cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). Item 2

Staking bore 45 degrees before TDC

Information
A data matrix coding is shown on the staking dihedron of the camshafts. This is a square black/white dotted marking used for electronic identification purposes during the production process. This marking can be used as an aid when inserting the camshafts into the cylinder head. All four camshafts press against the valves the least when the data matrix coding is facing upwards during installation.

39. Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and coat bearing locations with normal multipurpose grease or engine oil. Position housings correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft housings evenly and gradually, and slowly tighten to the specified tightening torque. The camshafts must not be strained or tilted. Outlet camshafts and intake camshafts (also bank-specific) cannot be used interchangeably because of the bearing locations and length.

Camshaft identification on V8 turbo engine M48/51

A - Cylinders 1 to 4
B - Cylinders 5 to 8
1 - Outlet camshaft identification (green)
2 - Intake camshaft identification (blue)
3 - Intake camshaft identification (blue)
4 - Outlet camshaft identification (green)

Camshaft housing identification

- All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads
1 - Matching number for cylinder head/intake camshaft housing, cylinder 1 (E1)
2 - Matching number for cylinder head/intake camshaft housing, cylinder 2 (E2)
3 - Matching number for cylinder head/intake camshaft housing, cylinder 3 (E3)
4 - Matching number for cylinder head/intake camshaft housing, cylinder 4 (E4)
5 - Matching number for cylinder head/outlet camshaft housing, cylinder 1 (A1)
6 - Matching number for cylinder head/outlet camshaft housing, cylinder 2 (A2)
7 - Matching number for cylinder head/outlet camshaft housing, cylinder 3 (A3)
8 - Matching number for cylinder head/outlet camshaft housing, cylinder 4 (A4)
Pfeil - Direction of travel

Camshaft mount, cylinders 5 to 8

1 - Dowel sleeves
2 - Housing (intake)
3 - Screw, M6 x 70 Tightening torque: 13 Nm (9.5 ftlb.)
4 - Housing
5 - Screw, M6 x 35 Tightening torque: 13 Nm (9.5 ftlb.)
6 - Housing (outlet)
7 - Bearing surfaces (oil with engine oil)
A - Direction of travel

40. Move both hydraulic valves for camshaft control into installation position and fit them. Item 5

Camshaft control

1 - Screw, M12 Tighten fully after setting timing.
2 - Hexagon sleeve
3 - Camshaft controller
4 - Washer (reusable); replace if disassembled completely
5 - Hydraulic valve for camshaft control
6 - Screw, M5 x 12 - Tightening torque: 6 Nm (4.5 ftlb.)
A - Direction of travel

41. Insert oil vent line at the firewall side of cylinder 5 and screw it on. Grease sealing ring sparingly with Kluber Syntheso GLEP 1.

Vent line

1 - Vent line to cylinder head/crankcase/oil pump
2 - O-ring
3 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Check valve
A - Direction of travel

42. Fit threaded peg for tensioning and guide rails. Items 1 and 2

Timing chain and chain guide

1 - Threaded peg - Tightening torque: 35 Nm (26 ftlb.)
2 - Threaded peg - Tightening torque: 20 Nm (15 ftlb.)
3 - Guide rail
4 - Tensioning rail
5 - Chain tensioner with sealing ring
6 - Pin (for locking the oil-pump tensioning rail)
A - Direction of travel

43. Fit guide rail with oil pump chain tensioning rail and pull locking pin (tensioning rail will be released).
44. Fit "U"-shaped deflection rail item 4.

Timing chain and sprockets

1 - Double-chain camshaft drive
2 - Camshaft sprocket
3 - Screw, M12 Tighten fully after setting timing.
4 - Deflection rail
5 - Screw, M8 x 35 - Tightening torque: 32 Nm (24 ftlb.)
6 - Camshaft-to-camshaft guide pad
A - Direction of travel

45. Fit tensioning rail and let it hang.
46. Fit both small guide rail pieces between the camshaft controller and sprocket.
47. Loosely fit camshaft controller and sprockets using screws (do not forget new diamond washer under the camshaft controllers).
48. Position timing chain and guide correctly over guide and tensioning rails.
49. Fill Loctite 5900 (000.043.204.35 status 04/07) first into the opening of the seal for the timing-case cover. Apply sealant as shown in the illustrations. Install the timing-case cover within 5 minutes.

Timing-case cover seals

1 - Timing-case cover
2 - Timing-case cover seal, outer right (fill openings with sealant, see 6)
3 - Timing-case cover seal, inner
4 - Timing-case cover seal, rib
5 - Timing-case cover seal, outer left (fill openings with sealant, see 6)
6 - Applying sealant to timing chain housing; Loctite 5900 (000.043.204.35 status 04/07)
A - Direction of travel

Applying sealant (fill openings in metal seal with sealant)

50. Move timing-case cover with pre-fitted metal seals into installation position (carefully insert oil vent line, grease sealing ring sparingly with Kluber Syntheso GLEP 1 if necessary). When doing so, press the tensioning rail away from the sprocket at the timing chain using a screwdriver (second worker required). Position timing-case cover.
51. Fit the timing-case cover using four to six screws. Align timing-case cover with the edge of the lower part of the crankcase (realign using plastic hammer if necessary). Fit remaining screws. Check projection again with respect to the lower part of the crankcase and realign if necessary. The timing-case cover can be adjusted using a dial gauge, steel rule or by touch (projection of timing-case cover with respect to the lower part of the crankcase). It should not be possible to feel or measure any projection on either side of the timing-case cover.

Example: Adjusting timing-case cover using a dial gauge

52. Insert the dial gauge into the universal gauge holder and position it so that the dial gauge has a preload of about 1 mm.

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 sheet metal holders under the screws.

Tightening sequence for timing-case cover

A - Aluminium screw, M6 x 30; timing-case cover to crankcase and cylinder head; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
B - Aluminium screw, M6 x 55; inner timing-case cover to upper part of crankcase and cylinder head; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees; outer timing case cover to cylinder head - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
C - Aluminium screw, M8 x 55; timing-case cover (chain tensioner position) to upper part of crankcase and cylinder head; always use new aluminium screws; - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90 degrees
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 - Aluminium screw M6 x 20; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
3 - Aluminium screw M6 x 55; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
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 - Aluminium screw; always use new aluminium screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees; oil-level sensor to oil guide housing (steel screw) - Tightening torque: 12 Nm (9 ftlb.); oil guide housing to lower part of crankcase, aluminium screw; always use new aluminium screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
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.

Oil lines on turbo engine (M48/51)

1 - Oil extraction line for turbocharger, cylinders 1 to 4
2 - Oil extraction line for turbocharger, cylinders 5 to 8
3 - Intake pipe on oil pump
4 - O-ring
5 - Oil pressure pipe
6 - O-ring
7 - O-ring, 22 x 3
8 - Oil regulating line
9 - O-ring
10 - O-ring
11 - 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.); turbocharger extraction line to oil pump - Tightening torque: 12 Nm (9 ftlb.)
12 - Screw, M6 x 20 - Tightening torque: 12 Nm (9 ftlb.)
A - For arrangement of oil lines, see other illustrations
B - Direction of travel

Oil lines, intake pipe on turbo engine M48/51

1 - Mount for oil extraction line for turbocharger, cylinders 1 to 4
2 - Mount for oil extraction line for turbocharger, cylinders 5 to 8
3 - Mount for oil separator vent line, cylinders 5 to 8
4 - Mount for oil pump intake manifold
6 - Mount for oil pressure pipe
9 - Mount for oil regulating line
A - Direction of travel

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 Aluminium screw; always use new aluminium screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees; oil-level sensor to oil guide housing (steel screw) - Tightening torque: 12 Nm (9 ftlb.) oil guide housing to lower part of crankcase, aluminium screw; always use new aluminium screws - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
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
Objects or loads failing down
Risk of squashing or crushing

- Secure components to prevent them from falling down.

Information
Support the engine at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block.

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

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