Part 1
WM 1001Z2 Assembling V8 4.8 liter DFI engine
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!
Assembling V8 4.8 liter DFI engine
Preliminary work for assembling V8 4.8 liter DFI engine
Caution:
Emerging residual fluid can soil the engine!
Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time when disassembling and assembling the engine.
- Place a drip tray under the engine at the assembly support.
- Have a sufficient number of cleaning cloths ready.
- Close off engine openings with plugs.
Information:
000 043 204 68 (Status 02107) "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.
Information:
All tightening torques, tightening sequences and assembly overviews are published in the corresponding document.
Many details are provided in the corresponding individual repair instructions.
Check that the following assembly preconditions have been met:
Oil guide housing pre fitted with oil filter and oil/water heat exchanger.
Check both oil mist separators to ensure that both side seals and both sealing rings have been pre fitted at the middle connection piece.
Check cylinder head cover (valve cover) to ensure that surrounding seal, seals for spark plug recesses, seal for hydraulic valve of camshaft control, hall sender for camshaft and oil filler cover are fitted.
Intake air distributor with seals, heat socket, screws and throttle housing inserted.
Generator with both fitted coolant connection pieces and sheetmetal cable holders.
Upper part of crankcase fitted on flywheel side with two water plugs. Two blue anodized screw plugs fitted on flywheel side under starter flange and on timing case side.
The upper part of the crankcase is located together with the engine support engine support P 9676 attached to the assembly support. Use the four screws mounting elements 9590 and tighten them.
Crankcase on engine support (shown with inverted top section of crankcase of disassembled engine)
Assembling V8 4.8 liter Turbo DFI engine
Caution:
Risk of damage due to particles of dirt.
Danger of material damage due to blocked oil bores/oil ducts.
- Absolute cleanliness is essential when working on the engine.
- Lay removed engine parts on a clean base and make sure to cover them.
- Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Caution:
Heavy components
Risk of squashing
- Wear personal protective gear.
- Get someone to help if necessary.
Caution:
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build up of condensation water or component distortion.
- Components must have reached at least 17°C throughout.
- Components must not be too hot (distortion).
- Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.
Caution:
Emerging residual fluid can soil the engine!
Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time when disassembling and assembling the engine.
- Place a drip tray under the engine at the assembly support.
- Have a sufficient number of cleaning cloths ready.
- Close off engine openings with plugs.
Information:
Connecting rod bolts must always be replaced.
Information:
All tightening torques, tightening sequences and assembly overviews are published in the corresponding document.
Many details are provided in the corresponding individual repair instructions.
1. Place crankshaft bearing shells into the lower part of the crankcase.
Information:
The bearing shells are available in various classes. The classes are indicated by the color marking on the outside. For every bearing (main and connecting rod bearings), the color marking must match the corresponding letter on the flywheel flange of the crankshaft. -arrow- Each letter on the flywheel flange of the crankshaft indicates the correct color classification of the bearing shell.
Color marking on bearing shell
1.1 Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9-. Example: YYYYB YYYY mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The letters are the abbreviations for the color code of the bearing shells (Y for yellow, B for blue, R for red). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells should all have a yellow marking in this case.
Crankshaft
1 - Crankshaft (stroke: 83 mm)
2 - Straight pin, 6 x 20
3 - Spring, 5 x 6.5
4 - Thrust washer
5 - Main bearing shell, upper
6 - Main bearing shell, lower
7 - Shaft seal
8 - View of crankshaft flange
9 - Crankshaft bearing classification (example: YYYYY-BBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting-rod bearings with blue marking)
1.2. Place crankshaft bearing shells with lubricating groove and bore -2- into the upper part of the crankcase -1-. Smooth crankshaft bearing shells -3- belong in the lower part of the crankcase. Insert the thrust washers into the center with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.
Inserting bearing shells
Inserting bearing shells
Thrust washer
1.3. Oil crankshaft bearing shells on the outside and inside with engine oil and insert correctly into the lower part of the crankcase according to the twist lock. Place lower part of crankcase on a clean surface. The retaining lugs (twist lock) prevent it from being installed incorrectly. As the thrust washers fall off without the crankshaft, do not insert until after the crankshaft is fitted.
2. If you have not already done so, fit knock sensors on the upper part of the crankcase using screws.
2.1. Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel to the cylinder head and the plug connection parallel to the starter. Fit knock sensors hand tight.
2.2. Insert starter briefly and align concealed knock sensors so that there is no knock sensor near the starter. Remove the starter. Fit plug connection for knock sensor between cylinders 3 and 4 in the direction of the water pump so that it is turned upwards and slightly towards the cylinder head. Fit plug connection for knock sensor between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards and slightly towards the cylinder head.
2.3. Fit knock sensors correctly.
Knock sensors
1 - Knock sensor
2 - Screw, M8 x 35 - Tightening torque: 23 Nm (17 ftlb.)
Seals between crankcase and thermostat housing
2.4. Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2-
3. Check coolant guide housing (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals on left and right -10-, screw in screws securely on metal seals by hand. Move coolant guide housing at upper part of crankcase into installation position and fit it -9-.
Coolant guide
1 - Coolant pipe
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
5 - Holding clamp
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
4. If you have not already done so, insert three screw plugs for the coolant guide housing with sealing ring and fit them (two in direction of transmission and one on the side close to cyl. 8).
5. Place dowel sleeves into upper part of crankcase if necessary and drive in using a copper or plastic hammer. When doing so, make sure that the dowel sleeves do not tilt. Fit two large dowel sleeves into the upper part of the crankcase on the flywheel side. Fit four large dowel sleeves into the upper part of the crankcase on the cylinder head side (two dowel sleeves for cylinder bank 1 to 4 and two dowel sleeves for cylinder bank 5 to 8). Fit two small dowel sleeves at the upper part of the crankcase on the thermostat housing side. Fit one small dowel sleeve at the lower part of the crankcase on the timing chain side (cyl. 5).
Upper part of crankcase
1 - Upper part of crankcase
2 - Lid
3 - Sealing ring
4 - Screw plug on upper part of crankcase
5 - Dowel sleeve
6 - Oil spray jet
7 - Screw, M6 x 16
6. Pre fit spring wedge into the corresponding groove of the crankshaft using a plastic hammer. -3-
Information:
The corresponding connecting rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
When removing the pistons with connecting rods, the pistons should be marked with a water resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A-. The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
Naturally aspirated engines and turbo engines have different pistons.
Connecting rod code and direction of travel arrow
Connecting rod code "A"
The code on the connecting rod big end and connecting rod cap must always be on the same side and at the exhaust side. -A- Note: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
7. Pre fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. To do this, perform the following steps.
Piston, connecting rod
1 - Piston-ring set
2 - Pistons
3 - Circlip/piston-pin circlip
4 - Piston pins
5 - Connecting rod
6 - Connecting rod bolt; replace as it must be tightened in the plastic area
7 - Connecting rod bearing shells
Connecting rod assembly, bearing shells
A - View A (identification area for connecting rod number; fit connecting rod with identification area facing exhaust side; markings on rod and lid must be on the same side)
B - View B (fit bearing shells flush and press into position)
C - View C (fit bearing shells flush and press into position
Piston classification
1 - Mahle control stamp
2 - Arrow marking in direction of travel
3 - Porsche short numeric code without main or middle number
4 - Cylinder bank identification
5 - Marking area for weight group
6 - Marking area for dimension group
7 - Barcode 128 (short numeric code (without main group) and weight group)
8 - Direction of travel arrow
9 - Mahle short numeric code
7.1. Select the pistons based on cylinder bank and pre fit a piston pin circlip. One end of the piston pin circlip is inserted into the ring groove of the piston pin eye -1-. Press the other end into the ring groove with your thumb. -finger- The opening of the piston pin circlip is pointing to 6 or 11 o'clock.
Piston pin circlip
7.2. Lever the piston pin circlip into the ring groove using a small screwdriver while continuing to press it down.
Inserting piston-pin circlip
7.3. If the piston pin circlip does not slide into the ring groove right away, press the other end of the piston pin circlip into the ring groove -arrow-. Check that the circlip is seated correctly.
Pressing piston pin circlip into ring groove
Information:
The corresponding connecting rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
When removing the pistons with connecting rods, the pistons should be marked with a water resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A-. The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
Connecting rod code and direction of travel arrow
Naturally aspirated engines and turbo engines have different pistons.
Connecting rod code "A"
The code on the connecting rod big end and connecting rod cap must always be on the same side and at the exhaust side. -A- Note: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
7.4. Turn piston and move connecting rod to the correct installation position. Insert connecting rod into piston.
Piston on retaining device
7.5. Oil piston pin and all contact points.
7.6. Fit piston pin using plunger 9500/8 and fit second piston pin circlip. Check for smooth operation.
Piston pin with plunger
7.7. Place piston, with the connecting rod fitted, on a soft surface. Do not use the vice to secure the connecting rod.
7.8. When fitting piston rings, the oil scraper ring is fitted first.
7.9. Carefully insert inner spring into the lower groove by hand, keeping it away from the piston crown.
7.10. Insert oil scraper ring over the inner spring into the groove by hand. "TOP" marking on piston rings must always be facing upwards to the piston crown. Spread piston rings just far enough for them to fit over the piston. Avoid straining the piston rings as this will result in permanent deformation of the piston ring.
7.11. Select both compression rings based on the height of the corresponding piston ring groove and install with the "TOP" marking facing the piston crown.
7.12. Clamp the piston ring gap using piston ring pliers or by hand and insert into the appropriate piston ring groove.
Piston ring pliers on piston ring
7.13. Twist piston ring gaps so that they are offset with respect to each other by 120°.
7.14. Oil piston rings and set down the assembly ready piston. Fit remaining pistons and connecting rods in the same way.
Information:
The corresponding connecting rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
When removing the pistons with connecting rods, the pistons should be marked with a water resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A-. The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
Connecting rod code and direction of travel arrow
Naturally aspirated engines and turbo engines have different pistons.
Connecting rod code "A"
The code on the connecting-rod big end and connecting rod cap must always be on the same side and at the exhaust side. -A- Note: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.
7.15. Select connecting-rod bearing shells based on the marking on the crankshaft flywheel flange and insert into the connecting rod big end and the connecting rod cap according to the twist lock. Fit connecting rod bearing cap onto the connecting rod big end again hand tight.
7.16. Place all eight pistons with the connecting rods fitted on a clean surface, sorted by cylinder.
8. Grease seal on thermostat insert sparingly with Kluber Syntheso GLEP 1 and fit it into the thermostat housing by hand. Press thermostat insert in as far as it will go.
9. Check that all the seals are installed in the oil plate.
Oil guide (oil plate)
10. If you have not already done so, drive eight dowel sleeves for the metal seals in the timing case cover using a copper or plastic hammer. Insert metal seals and press on dowel sleeves. Set down timing case cover.
11. Oil pump is pre fitted with the oil pressure control valve.
12. Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings, which have been marked according to installation position, can be set down on a clean surface together with the corresponding camshafts. Cam followers and injectors are fitted.
13. If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power steering pump or tandem pump using a copper or plastic hammer.
14. Move starter into installation position and screw down. - Tightening torque: 45 Nm (33 ftlb.)+8 Nm (+6 ftlb.)
15. Insert oil spray jets into upper part of crankcase and screw down - Tightening torque: 10 Nm (7.5 ftlb.). To do this, grease the sealing ring sparingly with Kluber Syntheso GLEP 1 and fit it. Check that oil spray jets are pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet must be aimed at the piston crown.
Spray direction
Spray direction from side
16. Insert crankshaft and oil crankshaft bearing pin and connecting rod bearing pin.
17. First position timing chain pinion with the ring gear of the oil pump drive onto the crankshaft stub (check that the two diamond washers at the front and rear on the ring gear are clipped in -1-). Then position the drive pinion of the oil pump chain -2- with respect to the crankcase.
Timing chain pinion on crankshaft stub
Timing chain pinion with two diamond washers
18. Fit crankshaft holding bridge holding bridge 9677/1 in the center of the crankshaft.
Crankshaft secured