Part 1

WM 1001Z2 Assembling V8 4.8-litre DFI engine as of October 2008

Tools

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.

Assembling V8 4.8-litre DFI engine as of October 2008

Preliminary work for assembling V8 4.8-litre 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 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.

Information

- All tightening torques, tightening sequences and assembly overviews are published in the corresponding document. -> 1001IN Tightening torques, tightening sequences, assembly overviews for V8 4.8-litre DFI naturally aspirated and turbo engines

- 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 anodised 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)

Crankcase on engine support (shown with inverted top section of crankcase of disassembled engine)

Assembling V8 4.8-litre Turbo DFI engine as of October 2008

CAUTION

Ingress 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.

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

Have a collection pan and some cloths ready before starting work on the engine block. Close off open hoses immediately after opening them using suitable stoppers. Residual fluid can leak out.

Information

- The bearing shells are available in various classes. The classes are indicated by the colour marking on the outside. For every bearing (main and connecting rod bearings), the colour 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 colour classification of the bearing shell.

Colour marking on bearing shell

Information

- Connecting rod bolts must always be replaced.

Information

- All tightening torques, tightening sequences and assembly overviews are published in the corresponding document. -> 1001IN Tightening torques, tightening sequences, assembly overviews for V8 4.8-litre DFI naturally aspirated and turbo engines

- Many details are provided in the corresponding individual repair instructions.

1. Place crankshaft bearing shells into the lower part of the crankcase.
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 colour code of the bearing shells (Y for yellow , B for blue , R for red , N for green ). 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

1.2. 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 centre with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.

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

2.4. Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2-

Seals between crankcase and thermostat housing

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

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

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

- 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.

Connecting rod code "A"

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

Connecting-rod assembly, bearing shells

Piston classification