Part 4

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

45. Fit tensioning rail and let it hang.
46. Fit both small guide rail pieces between the camshaft controller and sprocket.
47. Loosely fit camshaft controller and sprockets using screws (do not forget new diamond washer under the camshaft controllers).
48. Position timing chain and guide correctly over guide and tensioning rails.
49. Fill Loctite 5900 (000.043.204.35 status 04/07) first into the opening of the seal for the timing-case cover. Apply sealant as shown in the illustrations. Install the timing-case cover within 5 minutes.





Timing-case cover seals









Applying sealant (fill openings in metal seal with sealant)

50. Move timing-case cover with pre-fitted metal seals into installation position (carefully insert oil vent line, grease sealing ring sparingly with Kluber Syntheso GLEP 1 if necessary). When doing so, press the tensioning rail away from the sprocket at the timing chain using a screwdriver (second worker required). Position timing-case cover.
51. Fit the timing-case cover using four to six screws. Align timing-case cover with the edge of the lower part of the crankcase (realign using plastic hammer if necessary). Fit remaining screws. Check projection again with respect to the lower part of the crankcase and realign if necessary. The timing-case cover can be adjusted using a dial gauge, steel rule or by touch (projection of timing-case cover with respect to the lower part of the crankcase). It should not be possible to feel or measure any projection on either side of the timing-case cover.Example: Adjusting timing-case cover using a dial gauge
52. Insert the dial gauge into the universal gauge holder and position it so that the dial gauge has a preload of about 1 mm.





Adjusting preload

53. Set dial gauge scale to 0. To do this, place the dial gauge holder on a completely flat surface (e.g. crankcase) and turn the dial gauge scale until the pointer is at 0.





Setting dial gauge scale to zero

54. Measure offset. In order to do this, push with the holder starting from the lower part of the crankcase towards the timing-case cover (the foot of the dial gauge holder is not located on the same component as the dial gauge probe) and measure the offset. The timing-case cover must not be set back any more than 0.1 mm. A projection is not permissible.





Measuring offset

55. Align the timing-case covers by tapping lightly with a rubber hammer.





Aligning chain case lid

56. Then check the position of the timing-case cover again with the dial gauge.





Checking

57. Fit timing-case cover according to specifications. When doing so, do not forget any of the sheetmetal holders under the screws.





Tightening sequence for timing-case cover





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





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





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





64. Equip intake manifold oil strainer with sealing ring and then fit it. Tighten all oil pipes.





Oil lines on turbo engine (M48/51)









Oil lines, intake pipe on turbo engine M48/51





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 the 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

Objects or loads falling down

- Risk of squashing or crushing

-> Secure components to prevent them from falling down.

Information

Support the engine at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block.

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 DFI high-pressure pump - 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" Service and Repair
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" Overhaul
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 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