Part 4
WM 1001Z2 Assembling V8 4.8 liter DFI engine (continued)
Tightening sequence for timing case cover
A - Screw, M6 x 25 - Tightening torque: 13 Nm (9.5 ftlb.)
B - Screw, M6 x 50; inner timing-case cover to upper part of crankcase and cylinder head - Tightening torque: 13 Nm (9.5 ftlb.); timing case cover to cylinder head - Tightening torque: 13 Nm (9.5 ftlb.)
C - Screw, M8 x 50; timing case cover (chain tensioner position) to upper part of crankcase and cylinder head - Tightening torque: 23 Nm (17 ftlb.)
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 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
3 - Screw, M6 x 50 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Sealing ring
5 - Chain tensioner
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 - Dreibond Silikon FD 2210 sealing compound (000.043.204.58 status 04/07)
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 - 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
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 - 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
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 side line 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 damper 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.
Supporting engine (illustration shows V8 4.5-liter engine supported on assembly support)
71. Tighten vibration balancer to the specified torque (use 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
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
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 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. 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