Part 4
WM 1001Z2 Assembling V8 4.8-litre DFI engine as of October 2008
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
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. Fit adapter plate for power-steering pump if necessary.
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 of tank vent to the second upper screw of the timing-case cover at the 1st cylinder.
92. Fit PCV lines.
Positive crankcase ventilation (PCV), turbo engine M48/51
93. 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" Overhaul
94. Fit coolant hosing and secure clamps.
Coolant return line on turbo engine M48/51
Coolant supply line on turbo engine M48/51
95. 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
96. Lay boost-pressure control and circulating air lines at the engine and clip in at the cable duct.
Boost pressure and wastegate
Boost pressure and wastegate 2
97. 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 turbo engine M48/51, 6-piston pump
98. 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
99. 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
