Part 3
WM 1001Z2 Assembling V8 4.8-litre DFI engine up to October 2008
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)
Oil lines, intake pipe on naturally aspirated engine M48/01
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
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
67. Turn engine around.
68. Position vibration balancer with screw tightened by hand.
69. Set the timing. Follow procedure exactly. -> 150516 Setting camshaft timing on 4.8-litre DFI engines Procedures
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 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-litre engine supported on assembly support)
Pulleys
72. Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see -> 246319 Removing and installing high-pressure pump on DFI engines - section on "Installing" 246319 Removing and installing DFI high-pressure pump
73. Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.
Vacuum pump
74. Fit spark plugs if necessary. -> 287020 Removing and installing spark plugs on DFI engines - section on "Installing" 287020 Removing and installing spark plugs on DFI engines
75. Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see -> 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
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
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
80. Fit water pump. -> 195019 Removing and installing coolant pump on DFI engines - section on "Installing" Service and Repair Fit pulley for water pump.
81. Fit oil pressure sensor with adapter. Replace sealing rings.
Oil pressure sensor and oil pressure measuring point
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
Right bracket for auxiliary units and engine mounting
83. Fit cable clips (sheet-metal clips to the unit brackets and valve covers.
84. If necessary, fit adapter plate for power-steering pump.
Auxiliary units
85. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
Coolant supply line on naturally aspirated engine M48/01
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.
Left bracket for auxiliary units and engine mounting
Right bracket for auxiliary units and engine mounting
87. Position generator.
Generator
88. Position generator's crash support.
89. Screw down generator's crash support and generator. -> 272219 Removing and installing generator - section on "Installing" Service and Repair
90. Fit deflection rollers and belt tensioner and press on cover.
Belt drive
91. If you have not already done so, secure sheetmetal holder for tank vent to the second upper screw on the timing-case cover at the 1st cylinder.
92. Fit crankshaft sealing ring on flywheel side. See -> 135919 Removing and installing sealing ring for crankshaft (transmission side) on 4.8-litre DFI engines - section on "Installing" 135919 Removing and installing sealing ring for crankshaft (transmission side) on 4.8-litre DFI engines
93. Fit coolant hosing and secure clamps.
Coolant return line on naturally aspirated engine M48/01
Coolant supply line on naturally aspirated engine M48/01
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. For details, see -> 975219 Removing and installing engine wire harness - section on "Installing" 975219 Removing and installing wire harness for engine
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
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
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
98. 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
99. 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
100. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
Exhaust manifold on naturally aspirated engine M48/01, cylinders 1 to 4
Exhaust manifold on naturally aspirated engine M48/01, cylinders 5 to 8
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
Lambda sensor on naturally aspirated engine M48/01, cylinders 5 to 8
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)
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. For details, see -> 244619 Removing and installing intake-air distributor on DFI engines - section on "Installing" 244619 Removing and installing DFI intake-air distributor
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. For details, see -> 105519 Removing and installing oil mist separator on 4.8-litre DFI engines - section on "Installing" Service and Repair
105. Fit power-steering pump. -> 489819 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) - section on "Installing" 489819 Removing and installing hydraulic pump (PDCC)
106. Fit air conditioning compressor. -> 873419 Removing and installing air conditioning compressor - section on "Installing" Service and Repair
107. Fit pulley for power-steering pump or tandem pump.
Pulleys
108. 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
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.
Subsequent work
1. Fill in engine oil.
2. Remove engine from engine support.
3. Mount the engine on the transmission. -> 100127 Removing engine from transmission and mounting engine on transmission - section on "Mounting" 100127 Removing engine from transmission and mounting engine on transmission
4. 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