Removal and Replacement
WM 153319 Removing and installing timing-case cover on 4.8-litre DFI engines
Technical values
Information
Component changes for model year 2009 as of October 2008
Information
Always read the information concerning modified tightening specifications and component changes relating to repairs provided for specific engine numbers in the Information section -> 1001IN IMPORTANT component changes for V8 engines as of October 2008 1001IN IMPORTANT component changes for V8 engines as of October 2008.
Preliminary work
1. Remove engine. -> 100119 Removing and installing V8 4.8-litre DFI engine - section on "Removing" 100119 Removing and installing V8 4.8-litre DFI engine
2. Remove engine from transmission -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing engine from transmission and mounting engine on transmission and let it hang on the assembly support -> 1001IN Securing V8 4.8-litre DFI engine on assembly support 1001IN Securing V8 4.8l DFI engine on the mounting bracket.
3. Drain engine oil. For details, see -> 170117 Changing engine oil and oil filter on DFI engines Service and Repair
4. Remove drive belt. For details, see -> 137819 Removing and installing drive belt on 4.8-litre DFI engines - section on "Removing" 137819 Removing and installing drive belt on 4.8 l DFI engine
5. Remove coolant hoses in front of the timing-case cover. Don't forget the holder. => Coolant hose package
Coolant hose package
6. Remove both valve covers. -> 158219 Removing and installing cylinder head cover (valve cover) on 4.8-litre DFI engines - section on "Removing" 158219 Removing and installing cylinder head cover (valve cover) on 4.8-litre DFI engines
7. Remove vibration damper. -> 137619 Removing and installing vibration damper (crankshaft pulley) on 4.8-litre DFI engines - section on "Removing"
8. Remove joint flange behind the vibration damper and do not re-installed old flange. -> 137419 Removing and installing sealing ring for vibration balancer on DFI engines - section on "Removing"
9. Remove oil pan and oil guide housing. -> 175019 Removing and installing oil pan and oil guide housing on 4.8-litre DFI engines - section on "Removing" Removal and Replacement
Information
Component overview
Timing-case cover seals
Chain tensioner, joint flange
Removing timing-case cover
NOTICE
Timing-case cover removed incorrectly
- Risk of damage to seal between oil pan and crankcase
- Risk of engine leaks
-> Always reseal the oil pan when removing the timing-case cover.
1. Remove belt tensioner and deflection rollers on the timing-case cover. To do this, lever off the cover and loosen the screws. => Belt drive
Belt drive
2. Unclip vacuum lines at the cable duct -arrows-.
Unclipping vacuum lines at the cable duct
3. Release cable duct at the front right.
3.1. Unscrew fastening screw on oil dipstick -11- ( -arrow- ).
3.2. Unscrew fastening screw -12- on the cable duct -arrow-.
Releasing cable duct at the front right
4. Remove guide tube with oil dipstick. -> 171719 Removing and installing guide tube for oil dipstick on DFI engines - section on "Removing" Service and Repair
5. Remove chain tensioner. -> 153619 Removing and installing chain tensioner on 4.8-litre DFI engines - section on "Removing" Removal and Replacement
6. Remove timing-case cover. To do this, loosen all screws in reverse order. => Tightening sequence for timing-case cover
Tightening sequence for timing-case cover
7. Carefully remove timing-case cover. Lever off gently if necessary (bonded with sealant).
Information
Modification to timing-case cover seal from mid-2010
Information
- A modified metal seal has been used for the timing-case cover since mid-2010.
- The modified metal seal has an open cut-out on the side for applying sealant instead of the closed top opening.
- Existing metal seals can be used up.
- The sealant must be applied along the new contour as shown in the illustration.
- The small, closed top openings are filled with sealant in the familiar way.
Sealant application - new
Sealant application to right cylinder bank near the chain tensioner -1 and 2-
Sealant application to left cylinder bank -7 and 8-
Installing timing-case cover
Information
If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can occur because of condensed water forming or components distorting. Components must be uniformly at least => Temperature: 17°C.
Information
- Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more sealant.
1. Clean dirt and grease off the sealing faces of the engine and timing-case cover.
2. Fit the new metal seals on the timing-case cover. Fill the openings in the metal seals with sealant. Apply sealant at the specified markings on the engine => Timing-case cover seals => Applying sealant (fill openings in metal seal with sealant). Apply the sealant in such a way that no excess sealant can expand into the engine when the timing-case cover is fitted (blocked oil ducts).
Timing-case cover seals
Applying sealant (fill openings in metal seal with sealant)
3. When fitting the timing-case cover, press the tensioning rail away from the sprocket (cylinder 1) towards the timing chain using a screwdriver (second worker required).
4. Fit timing-case cover straight on without letting it slip out of place.
5. Screw down all fastening screws by hand. At this stage, the screw heads should not be all the way down.
Information
- The timing-case cover must be aligned using a dial gauge or steel gauge.
- The timing-case cover must not project over the lower part of the crankcase. Even the slightest projection must be corrected.
- It must not be less than ( -dimension A- )1/10 mm ( -dimension A < 1/10 mm- ).
6. Press the timing-case cover upwards slightly and tighten the fastening screws (approx. 1 - 2 Nm (0.5 - 1.5 ftlb.) so that the timing-case cover is slightly jammed. Then align the timing-case cover.
Aligning timing-case cover with a dial gauge
Information
The timing-case cover must not project over the crankcase. The maximum offset is => Length: 0.1 mm.
1. Insert the dial gauge into the universal dial gauge bracket and position it so that the dial gauge has a preload of about 1 mm. => Adjusting the preload
Adjusting the preload
2. Set dial gauge scale to 0. To do this, place the dial gauge bracket on a completely flat surface (e.g. crankcase flange) and turn the dial gauge scale until the pointer is at 0. => Resetting dial gauge scale
Resetting dial gauge scale
3. Measure offset. To do this, push with the bracket starting from the lower part of the crankcase towards the timing-case cover (the base of the dial gauge bracket is not located on the same component as the dial gauge probe) and measure the offset => Measuring the setback distance. The timing-case cover must not be set back by more than 0.1 mm. Even the slightest projection must be corrected.
Measuring the setback distance
4. Align the timing-case covers by tapping lightly with a rubber hammer. => Aligning timing-case cover
Aligning timing-case cover
5. Once you have aligned the timing-case cover, tighten two fastening screws on the left and right of the timing-case cover base hand-tight. Then check the position of the timing-case cover again using the dial gauge. => Checking position
Checking position
Securing timing-case cover
Securing timing-case cover as of October 2008
1. Tighten the remaining fastening screws to the appropriate torque in the order shown. => see figure
Tightening sequence for timing-case cover
Carry out further assembly work =>
2. Secure cable duct at the front right.
2.1. Route cable duct on the timing-case cover.
2.2. Secure cable duct on the timing-case cover with the fastening screw -12- ( -arrow- ). => Tightening torque: 10 Nm (7.5 ftlb.) ; when using aluminium screws (partial mixed installation) => Initial tightening: 4 Nm (3 ftlb.) and => Final tightening: 90°
2.3. Fit guide tube with oil dipstick. -> 171719 Removing and installing guide tube for oil dipstick on DFI engines - section on "Installing" Service and Repair
2.4. Secure oil dipstick with the fastening screw -11- ( -arrow- ). => Tightening torque: 10 Nm (7.5 ftlb.)
Securing cable duct at the front right
3. Clip in vacuum lines at the cable duct -arrows-.
Clipping in vacuum lines at the cable duct
4. Fit belt tensioner and deflection rollers on the timing-case cover. Fit screws and cover. => Belt drive
Belt drive
Subsequent work
1. Install oil guide housing and oil pan. -> 175019 Removing and installing oil pan and oil guide housing on 4.8-litre DFI engines - section on "Installing" Removal and Replacement
2. Fit new joint flange behind the vibration damper. -> 137419 Removing and installing sealing ring for vibration balancer on DFI engines - section on "Installing"
3. Set the timing. To do this, connect the vibration damper. -> 150516 Setting camshaft timing on 4.8-litre DFI engines Procedures
4. Fit vibration damper. -> 137619 Removing and installing vibration damper (crankshaft pulley) on 4.8-litre DFI engines - section on "Installing"
5. Install both valve covers. -> 158219 Removing and installing cylinder head cover (valve cover) on 4.8-litre DFI engines - section on "Installing" 158219 Removing and installing cylinder head cover (valve cover) on 4.8-litre DFI engines
6. Fit drive belt. For details, see -> 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
7. Fit coolant hoses in front of the timing-case cover. Don't forget the holder. => Coolant hose package
Coolant hose package
8. Fill in engine oil. For details, see -> 170117 Changing engine oil and oil filter on DFI engines Service and Repair
9. Mount engine on transmission. -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing engine from transmission and mounting engine on transmission
10. Install engine. -> 100119 Removing and installing V8 4.8-litre DFI engine - section on "Installing" 100119 Removing and installing V8 4.8-litre DFI engine