Installing 4.8-Litre DFI Engine

Special equipment-specific features are described in the notes. 

Fig 1: Lifting Platform

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1. -1- - Assembly mandrel  => Height can be adjusted; used for mounting in the engine carrier; equipped with a locking screw to prevent engine from tipping and for height adjustment. Item 2 in base carrier 
2. -2- - Wheel hub holder  => Secures the spring struts to prevent them from tipping. Inserted from the side into the second cross member from the front 
3. -3- - Assembly mandrel  => Height can be adjusted; used for mounting in the front-axle carrier at the front; equipped with a locking screw to prevent engine from tipping and for height adjustment. Item 1 in base carrier 
4. -4- - Support  => Not used here.
5. -5- - Wishbone support  => Used in conjunction with -5-  to protect the wheel suspension and spring struts from damage.
6. -6- - Assembly mandrel  => For mounting on the front-axle carrier at the rear. Item 3 in base carrier 
7. -7- - Assembly mandrel  => Guide for positioning the lifting platform into the body; first moves into a bore in the body for centring roughly. Item 4 in base carrier 
8. -8- - Assembly mandrel  => For mounting on the transmission cross member. Item 5 on base carrier 

1. Lift the engine at the take-up points provided on a workshop crane and set it down on the front-axle carrier.
2. Position the lifting platform with the engine/transmission unit under the body.
3. Raise the body to a comfortable working height using the lifting platform.

   Information 

   • Position the front-axle carrier back in its original, marked installation position and be careful not to damage adjacent parts. 
4. Raise the engine/transmission unit into the body using the lifting platform and make sure there is sufficient clearance.
   Fig 2: Guiding Engine/Transmission Unit Into Body With Lifting Platform

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   Information 

   • Make sure that the lines are not trapped. 
   1. 4.1. Freely-suspended lines (e.g. PDCC) must be routed in such a way that they go back into installation position.
   2. 4.2. The insertion guides -1, 3 and 4-  on the lifting platform must fit into the holes in the body. When doing so, use the markings used for removal as a positioning guide.
      Fig 3: Lifting Platform

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5. Tighten four fastening screws -arrows-  on the front-axle carrier. → Installing Front-Axle Carrier
   Fig 4: Locating Threaded Joint On Chassis Subframe

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6. Tighten two fastening screws -arrow-  on the engine transverse bar. → Initial tightening: 120 Nm (89 ft lbs.) → Final tightening - torque angle: 180° 
   Fig 5: Locating Engine Carrier Mounting

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7. Tighten four fastening screws -1-  on the transmission support. → Initial tightening: 50 Nm (37 ft lbs.) → Final tightening - torque angle: 90° 
   Fig 6: Fastening Screws On Transmission Cross Member

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8. Loosen lateral supports on the wheel hubs.
   Fig 7: Supporting Wheel Hub

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9. Slowly lower the lifting platform and remove it.
10. Connect electric connectors -1, 2 and 3-  to the transmission and clip in the wire harness.
    Fig 8: Locating Transmission Electric Connectors

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11. Secure the heat shield above the right electric connections -1, 2 and 3-. 
    Fig 9: Identifying Connectors On Transfer Gear

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12. Fit refrigerant lines. → Installing Air Conditioning Compressor .
    Fig 10: Securing Refrigerant Lines On Air-Conditioning Compressor

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13. Connect cable plug to the air-conditioning compressor.
14. Fit connections for the PDCC lines around the front axle. Counter screw torque. For tightening torques, see → WM 4300TW TIGHTENING TORQUES
    1. 14.1. Fit the two lines -arrows-  on the front right side member.
       Fig 11: Locating Front Right PDCC Lines

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    2. 14.2. Position lines in the valve block -arrows-  in the right wheel housing and tighten.
       Fig 12: Locating PDCC Line In Right Wheel Housing

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    3. 14.3. Fit and tighten line -arrow-  on the distributor under the front-axle final drive.
       Fig 13: Locating PDCC Line On Distributor Under Front-Axle Final Drive

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    4. 14.4. Fit and tighten PDCC line -arrow-  on the front axle.
       Fig 14: Locating PDCC Line On Front Axle

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15. Turbo engine: 

    Fit hose -3-  between the ambient air valve and intake pipe -1-  on both sides  by fastening the hose clamp -2-  .

    Fig 15: Identifying Connection Between Ambient Air Valve Hose And Intake Pipe

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16. Fit selector lever cable to transmission. To do this, press the ball socket -arrow-  onto the ball. Then slide the upper sheetmetal clip -1-  into position.
    Fig 16: Locating Selector Lever Cable On Transmission

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17. Push the power-steering fluid line onto the cooler -arrow-  and fit the spring band clamp.
    Fig 17: Locating Spring Band Clamp On Power-Steering Fluid Line

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18. Fit the steering column onto the steering gear. → Installing Steering Gear
    Fig 18: Locating Steering Column On Steering Gear

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19. Fit the heat shield on the steering gear using two fastening screws -arrows-  . → → Tightening torque: 10 Nm (7.5 ft lbs.) 
    Fig 19: Locating Fastening Screws Securing Heat Shield To Steering Gear

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    Information 

    • For vehicles with Servotronic, the electric connector on the steering gear must also be connected  .
20. Fit electric connector -arrow-  on the steering gear (Servotronic only). Figure shows right-hand drive vehicle.
    Fig 20: Locating Servotronic Cable Plug

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21. Slide the heater coolant lines -arrows-  onto the left side member and fit the clips.
    Fig 21: Locating Heater Coolant Lines On Left Side Member

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22. Attach coolant connection piece -arrow-  at the top left of the radiator. The connection piece must engage audibly.
    Fig 22: Locating Coolant Connection Piece

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23. Connect ATF lines to the radiator. Remove stoppers -arrow-  and fit the lines. → Installing Line For ATF Cooling
    Fig 23: Connecting ATF Lines

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24. Fit the ground point of the generator -arrow-  on the right side member. → Tightening torque: 20 Nm (15 ft lbs.) 
    Fig 24: Locating Generator Ground Point

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25. Turbo engine: 

    Fit the two pressure pipes. Push pressure pipes into connections and fit spring band clamp. The couplings -1-  must lock with an audible click. -1- 

    Fig 25: Locating Left Pressure Pipe

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    Fig 26: Locating Boost Pressure Pipe

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26. Install rear cardan shaft. → WM 393519 REMOVING AND INSTALLING REAR CARDAN SHAFT
27. Fit exhaust system. Move exhaust system into position using a transmission jack or get a second person to assist you. → Installing Exhaust System
    Fig 27: Fitting Exhaust System On Transmission Jack

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28. Secure the catalytic converter holders on the body. → Tightening torque: 23 Nm (17 ft lbs.)  .
    Fig 28: Locating Fastening Screws On Body And Cross Member

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29. Lower the vehicle halfway.
30. Vehicles with air suspension: 
    1. 30.1. Fit air suspension hose -arrow-  .
       Fig 29: Locating Compressed Air Line

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    2. 30.2. Plug in cable plug -arrow-  on sensor for headlight levelling system.
       Fig 30: Locating Sensor For Headlight Levelling System

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31. Tighten brake lines -arrow-  .
    Fig 31: Locating Brake Lines In Wheel Housings

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32. Fit electric connector for wear indicator -1-  .
    1. 32.1. Press in holders -2 and 3-  .
       Fig 32: Locating Cable Guide At Spring Strut 2

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33. Fit ABS sensor cable at spring strut 1 and connect cable plug.
    1. 33.1. Plug in sensor on air spring strut.
       Fig 33: Locating Cable Guide At Spring Strut 1

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34. Lower the vehicle.
35. Replace and screw in three fastening screws on the spring struts -1-  at the left and right. One screw is easily accessible in the plenum panel.

    → WM 4000TW TIGHTENING TORQUES FOR FRONT AXLE (ALL MODELS) →

    Fig 34: Locating Spring Strut Screws

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    Fig 35: Locating Spring Strut View From Wheel Housing

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36. Mount B+ transfer point on left spring dome. → Tightening torque: 23 Nm (17 ft lbs.) 
    Fig 36: Mounting B+ Transfer Point On Left Spring Dome

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37. Fit upper coolant pipe and both intake pipes (turbo engine) into the air cleaner housing. --
    Fig 37: Locating Upper Coolant Pipe And Both Intake Pipes (Turbo Engine)

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38. Fit hoses -2 and 3-  to the reservoir.
    1. 38.1. Vehicles with PDCC: 

       Use a clip to fit the PDCC reservoir -1-  .

    2. 38.2. Fill reservoir with the specified amount of fluid.
       Fig 38: Locating Reservoir Clips And Bolts

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39. Clip in engine wire harness -1-  and route into the plenum panel.
40. Fit line from the carbon canister -2-  to the plenum panel splash panel. Fit vacuum line -3-  . Fit fuel line -4-  to the plenum panel splash panel. → Tightening torque: 35 Nm (26 ft lbs.) 
    Fig 39: Identifying Lines On Plenum Panel

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41. Fit two coolant lines to the reservoir. -1 and 2- 
    Fig 40: Locating Coolant Hoses

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    Fit torque support → Secure torque support on engine → Tightening torque: 60 Nm (44 ft lbs.)  and torque support on body → Tightening torque: 60 Nm (44 ft lbs.). 

    Fig 41: Fitting Torque Support

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42. Connect vacuum line at the vacuum pump connection piece -arrow-  on the engine.
    Fig 42: Connecting Vacuum Line To Vacuum Pump

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43. Turbo engine: 

    Connect line to the ambient air valves -1-  . Prepare clip -2-  for correct installation position.

    Fig 43: Locating Line To Ambient Air Valves

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44. Turbo engine: 

    Connect the two cable plugs for the MAF sensor -1-  . Fit the PCV line -2-  on the right pressure pipe (PCV is positive crankcase ventilation).

    Fig 44: Locating PCV And MAF Sensor

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45. On V8 naturally aspirated engines, fit the intake pipe between the air cleaner housings. → Installing Air Box For Throttle Housing (Intake Pipe Upstream Of Throttle Valve)
46. Turbo engine:  Fit Y-shaped pipe ahead of the throttle valve. → Installing Air Box For Throttle Housing (Intake Pipe Upstream Of Throttle Valve)
47. Fit the two oxygen sensor connectors on the plenum panel at the left and right. Fit retaining clip straight on.
    Fig 45: Locating Oxygen Sensor Connectors

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48. Lay the engine wire harness -2-  in the plenum panel. Clip rubber sleeve -3-  into the plenum panel. Then guide the control unit connector to the right. Secure the control unit, connector and ground point -1-. → Tightening torque: 10 Nm (7.5 ft lbs.) 
    Fig 46: Identifying Engine Wire Harness In Plenum Panel

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49. Plug in connector -1 -  on the DME control unit -3-  and -arrows A-  close the latch -arrows B-  .
    Fig 47: Plugging In Connector

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50. Secure DME control unit with support.
    1. 50.1. Position DME control unit -3-  with holder -arrow A-  and secure in place with fastening screws -1-  .
    2. 50.2. Clip in wire harness -2-  at the holder -arrow B-  .
       Fig 48: Securing DME Control Unit With Holder

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51. Fit the two connectors for the engine wire harness -1 and 2-  (white, red) inside the central electrical system. Move the wire harness into installation position and fit into the retaining clips inside the plenum panel.
    Fig 49: Identifying Cable Plug And Connectors

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52. Fit the cover of the central electrical system on the side of the vehicle. To do this, screw in four Torx screws -arrows-  .
    Fig 50: Locating Torx Screws For Cover Of Central Electrical System

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