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Overhaul


WM 157019 Removing and installing cylinder head on 4.8-litre DFI engines

Technical values






Preliminary work

Information

- If more extensive work is planned, e.g. if the entire cylinder head is to be replaced, the exhaust manifolds, fuel injectors, high-pressure pump or vacuum pump must also be removed.

1. Remove the engine. => 100119 Removing and installing V8 4.8-litre DFI engine - section on "Removing"
2. Remove the engine and place it on the assembly support. => 100127 Removing engine from transmission and mounting engine on transmission - section on "Removing"
3. Remove the turbocharger from the exhaust manifold on V8 turbo engines. => 213019 Removing and installing turbocharger on 4.8-litre DFI engines - section on "Removing"
4. Remove the intake-air distributor. => 244619 Removing and installing DFI intake-air distributor - section on "Removing"
5. Remove the fuel distribution pipe. => 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Removing"
6. Remove the timing-case cover. => 153319 Removing and installing timing-case cover on 4.8-litre DFI engines - section on "Removing"
7. Remove the timing chain. => 153519 Removing and installing timing chain on 4.8-litre DFI engines - section on "Removing"
8. Remove the deflection rail. => 154719 Removing and installing guide and tensioning rails on 4.8-litre DFI engines - section on "Removing"
9. Remove the camshafts. => 150520 Removing and installing camshafts on 4.8-litre DFI engines - section on "Removing"

Information

Component overview





Cylinder head 1 to 4









Cylinder head 5 to 8









Tightening sequence for cylinder head






Removing cylinder head

1. Remove the vent line between the oil mist separator and cylinder head. To do this, unscrew the fastening screws -3-.





Vent line





2. Remove vent line.
2.1. Unscrew fastening screws -1-.
2.2. Unclip vent line -2- from the cable duct and remove it -arrow-.





Removing vent line

3. Expose the engine wire harness close to the vacuum pump. => Unclipping engine wire harness close to vacuum pump => Unclipping engine wire harness at the rear right





Unclipping engine wire harness close to vacuum pump





Unclipping engine wire harness at the rear right

4. Unclip the engine wire harness close to the high-pressure pump.
4.1. Unclip the engine wire harness at the retaining clips -arrows A-.
4.2. Unscrew the screw socket -arrow B-.





Unclipping engine wire harness close to high-pressure pump

5. Lift the wire harness up and out at the cylinder heads -arrow-





Removing engine wire harness

6. Remove mounting saddle at the front -8- (cylinder bank 1 to 4 shown). This hides the cylinder head screws underneath.





Camshafts, cylinder bank 1 to 4





7. Remove front M8 screw securing the cylinder head of cylinders 1 to 4 to the crankcase. -3-





Cylinder head 1 to 4

8. Remove cylinder head screws in the opposite order to the tightening sequence shown => Tightening sequence for cylinder head. Remove cylinder head. If necessary, remove the valve lifters now and lay them aside in the correct order.





Tightening sequence for cylinder head

9. Remove cylinder head gasket.
10. Remove cylinder head for cylinders 5 to 8 in the same way. => Cylinder head 5 to 8





Cylinder head 5 to 8

Installing cylinder head

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.

Information

- All sealing surfaces must be clean and free of grease.

- It is essential to work carefully.

- Tightening sequences and tightening torques must be observed.

1. Replace cylinder head gasket.
2. Place cylinder head gasket correctly, i.e. according to specifications, onto the straight pins on the engine crank housing. This must be done in such a way that the marking 'Top' can be read -see illustrations-.





Cylinder bank 1 -4





Cylinder bank 5 - 8

3. Fit cylinder head. Insert cylinder head screws (screws can be re-used). Refer to the component overview above for tightening specifications.





Cylinder head 1 to 4









Cylinder head 5 to 8





4. Fit front M8 screw to secure the cylinder head of cylinders 1 to 4 to the crankcase. -3-





Cylinder head 1 to 4

5. Fit the mounting saddle at the front -8- (cylinder bank 1 to 4 shown).





Camshafts, cylinder bank 1 to 4





6. Secure wire harness to the engine.
6.1. Position and lay engine wire harness on the engine housing -arrow-.
6.2. Tighten fastening screws. => Tightening torque: 10 Nm (7.5 ftlb.)





Securing engine wire harness on engine housing

7. Clip in engine wire harness at the rear right using the retaining clip -arrow-.





Clipping in engine wire harness at the rear right

8. Clip in engine wire harness close to the vacuum pump.
8.1. Clip in engine wire harness using the retaining clip -arrow A-.
8.2. Slide engine wire harness onto the holder -arrow B-.





Clipping in engine wire harness close to the vacuum pump

9. Clip in engine wire harness close to the high-pressure pump.
9.1. Screw in and tighten the screw socket -arrow A-. => Tightening torque: 23 Nm (17 ftlb.)
9.2. Clip in engine wire harness using the retaining clips -arrows B-.





Clipping in engine wire harness close to the high-pressure pump

10. Install vent line.
10.1. Position vent line -1- and clip it into the cable duct -arrow-.
10.2. Fit the fastening screws -2-. => Tightening torque: 10 Nm (7.5 ftlb.)





Installing vent line

11. Insert oil vent line at the firewall side of cylinder 5 and screw it on. Lightly grease the sealing ring.





Vent line






Subsequent work

1. Fit deflection rail. => 154719 Removing and installing guide and tensioning rails on 4.8-litre DFI engines - section on "Installing"
2. Install camshafts. => 150520 Removing and installing camshafts on 4.8-litre DFI engines - section on "Installing"
3. Fit timing chain. => 153519 Removing and installing timing chain on 4.8-litre DFI engines - section on "Installing"
4. Fit timing-case cover. => 153319 Removing and installing timing-case cover on 4.8-litre DFI engines - section on "Installing"
5. Set the timing. => 150516 Setting camshaft timing on 4.8-litre DFI engines - section on "Setting"
6. Fit the fuel distribution pipe. => 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Installing"
7. Fit intake-air distributor. => 244619 Removing and installing DFI intake-air distributor - section on "Installing"
8. Fit the turbocharger on V8 turbo engines. => 213019 Removing and installing turbocharger on 4.8-litre DFI engines - section on "Installing"
9. Take the engine from the assembly support and mount it on the transmission. => 100127 Removing engine from transmission and mounting engine on transmission
10. Install the engine. => 100119 Removing and installing V8 4.8-litre DFI engine - section on "Installing"
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