Installing Oil guide housing as of October 2008

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 

When installing the oil guide housing, make sure that it is perfectly aligned and that there is no dirt or dust between the components. Fit the oil guide housing straight. The maximum offset must be less than 0.1 mm and it must not project over the crankcase. Otherwise, leaks can occur while driving.

1. Clean sealing surfaces on the oil guide housing and crankcase. The sealing surfaces must be dry and free of grease.
2. Apply liquid sealant to the oil guide housing. Apply Doboseal 224N sealant (999.915.573.43, status 09/08) with the handheld cartridge. The contour of the sealing bead must comply with the figure shown below. The sealing bead should be approx. 1.0 mm wide and high. Ensure that the bead of sealant is continuous and that there are no gaps.
   Fig 1: Identifying Sealant Applying To Oil Guide Housing

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   1. Seal application (geometry, 1-mm bead of sealant)
   2. Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
   1. Direction of travel
3. Insert a new sealing ring into the ring groove on the lower part of the crankcase and bond it with a very small amount of grease.

   Information 

   • If the transmission or engine is removed, the oil guide housing must be aligned using a dial gauge. 
4. Place the oil guide housing on the crankcase and push evenly against the transmission bell housing.
5. Screw in a fastening screw on each corner of the oil guide housing and tighten screws by hand.

   Information 

   • If the transmission or engine is removed, the oil guide housing must be aligned using a dial gauge. 
6. Then screw in all screws by hand. While doing this, push the oil guide housing towards the transmission. Also fit the two transmission screws and tighten hand-tight.
7. Beginning at the transmission flange and proceeding forwards, tighten the screws evenly and crosswise. -6-  Do not forget the screws from the top to the timing-case cover.
   Fig 2: Locating Screws Between Timing-Case Cover And Oil Guide Housing

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   Fig 3: Identifying Oil Guide Housing With Accessories

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   1. Guide tube
   2. O-ring
   3. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   4. Oil dipstick
   5. O-ring
   6. Timing-case cover to oil guide housing Aluminium screw; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.)  and → Final tightening: 90°;  oil-level sensor to oil guide housing (steel screw) → Tightening torque: 12 Nm (9 ft lbs.);  oil guide housing to lower part of crankcase, aluminium screw; always use new aluminium screws → Initial tightening: 4 Nm (3 ft lbs.)  and → Final tightening: 90° 
   7. Oil level sensor
   8. O-ring
   9. Joint flange
   10. Screw, M6 x 20 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   11. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   1. Direction of travel
8. Tighten the bottom two screws between the transmission and oil guide housing. → For details, see → Installing Transmission
   Fig 4: Locating Screws Between Oil Guide Housing And Transmission

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9. After fitting the oil guide housing, the connecting tubes (oil lines and oil pipes) between the oil pump and oil guide housing must be fitted. On the Turbo, fit the side oil suction pipes. See Fig 5.
   Fig 5: Identifying Oil Lines On Turbo Engine (M48/51)

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   1. Oil extraction line for turbocharger, cylinders 1 to 4
   2. Oil extraction line for turbocharger, cylinders 5 to 8
   3. Intake pipe on oil pump
   4. O-ring
   5. Oil pressure pipe
   6. O-ring
   7. O-ring, 22 x 3
   8. Oil regulating line
   9. O-ring
   10. O-ring
   11. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing → Tightening torque: 12 Nm (9 ft lbs.);  oil control line to oil pump and oil guide housing → Tightening torque: 12 Nm (9 ft lbs.);  turbocharger extraction line to oil pump → Tightening torque: 12 Nm (9 ft lbs.) 
   12. Screw, M6 x 20 → Tightening torque: 12 Nm (9 ft lbs.) 
   1. For arrangement of oil lines, see other Fig 6
   2. Direction of travel
      Fig 6: Identifying Oil Lines On Naturally Aspirated Engine (M48/01)

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   1. Intake pipe on oil pump
   2. O-ring
   3. Oil pressure pipe
   4. O-ring
   5. O-ring
   6. Oil regulating line
   7. O-ring
   8. O-ring
   9. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing → Tightening torque: 12 Nm (9 ft lbs.);  oil control line to oil pump and oil guide housing → Tightening torque: 12 Nm (9 ft lbs.) 
   10. Screw, M6 x 20 → Tightening torque: 12 Nm (9 ft lbs.) 
       Fig 7: Identifying Oil Lines, Intake Pipe On Turbo Engine M48/51

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   1. 1 - Mount for oil extraction line for turbocharger, cylinders 1 to 4
   2. 2 - Mount for oil extraction line for turbocharger, cylinders 5 to 8
   3. 3 - Mount for oil separator vent line, cylinders 5 to 8
   4. 4 - Mount for oil pump intake manifold
   5. 6 - Mount for oil pressure pipe
   6. 9 - Mount for oil regulating line
   1. Direction of travel
      Fig 8: Identifying Oil Lines, Intake Pipe On Naturally Aspirated Engine M48/01

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   1. Mount for oil pump intake manifold
   2. Mount for oil separator vent line, cylinders 5 to 8
   3. Mount for oil pressure pipe
   4. Mount for oil regulating line