Part 5

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

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"
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"
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





100. 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
101. Check the DFI high-pressure system for leaks. -> 243001 Checking fuel distribution pipe (fuel rail) on DFI engines for leaks Testing and Inspection
102. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.





Tightening sequence for exhaust manifold on turbo engine M48/51, cylinders 1 to 4





Exhaust manifold on turbo engine M48/51, cylinders 1 to 4









Exhaust manifold on turbo engine M48/51, cylinders 5 to 8





103. Pre-fit the coolant and oil circuit lines, which are hard to reach when fitted, on the turbocharger.





Turbocharger, cylinders 1 to 4 - cooling









Turbocharger, cylinders 5 to 8 - cooling









Oil circuit for turbocharger, cylinders 1 to 4









Oil circuit for turbocharger, cylinders 5 to 8





104. Fit turbocharger with the pre-fitted lines with seal to the exhaust manifold. Make sure that the fitted lines are located in the approximate installation position. Fit screws. Fit bracket between the cylinder head and the turbocharger and screw it down. (Tightening torques: refer also to "Exhaust manifold")





Turbocharger, cylinders 1 to 4









Turbocharger, cylinders 5 to 8





105. Fit oil extraction lines onto the turbocharger and the oil guide housing. Fit vent lines to the oil extraction line and then along the coolant collection pipe.
106. Screw the turbocharger lines to the cylinder head and the coolant collection pipe. Fit coolant hoses.
107. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets.





Oil mist separator for positive crankcase ventilation (M48/51 turbo engine)





108. 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" Overhaul
109. 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"
110. Fit power-steering pump. -> 489819 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) - section on "Installing" 489819 Removing and installing hydraulic pump (PDCC)
111. Fit air conditioning compressor. -> 873419 Removing and installing air conditioning compressor - section on "Installing" Service and Repair
112. Fit pulley for power-steering pump or tandem pump.





Pulleys





113. 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" Service and Repair
114. Fit heat protection panels on generator and on exhaust manifold. => Tightening torque: 10 Nm (7.5 ftlb.)
115. Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.