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Tappets

Tappets

To remove

Warning

Work involving removal of the fuel rail involves interference with the car fuel system. The following points should therefore be observed in connection with the procedure:

• Ensure good ventilation! If there is approved ventilation for extraction of fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation of the skin.

• Have a fire extinguisher class BE at hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Wear protective glasses.



1. Remove the camshaft, see Camshaft,


2. Vacuum up any oil on top of the cylinder head.

3. Detach the air hose from the throttle body. Bend it to one side and plug it.

4. Bend aside the wiring harness duct.

5. Unplug the EGR valve.

6. Remove the throttle body.

7. Remove the bolts securing the EGR valve and move the valve to one side.

8. Remove the fuel return hoses

9. Note the position of the fuel rails and their clamps, and mark the rails.


10. Remove the fuel rails (the clamps can be removed if necessary).

11. Remove the upper part of the intake manifold and seal the passageways.


12. Remove the retaining screws for the fuel bridges, lift the fuel bridges and pull them out of the cylinder head.

13. Remove the valve bridges.

Important

Note how the valve bridges are fitted. The markings are on the side of the valve bridges facing the fuel bridges.


14. Lift up the valve tappets with 83 91 401 Magnetic tool .

15. Remove the seals on the injector connections in the cylinder head.


To fit


1. Clean all removed parts and inspect for wear. Change if necessary.

2. Fit new seals on the injector connections in the cylinder head.


3. Lubricate the valve tappets with engine oil and position them on the cylinder head.

4. Blow the holes for the fuel bridge retaining bolts clean.

5. Fit new O-rings on the fuel bridges, lubricate the O-rings with acid-free vaseline and slide the fuel bridges into the cylinder head.

6. Tighten the fuel bridge retaining bolts by hand using a socket and extension piece. Then use a ratchet handle to tighten them a further 360°.

7. Fit the valve bridges.

Important

Note how the valve bridges are fitted. The markings are on the side of the valve bridges facing the fuel bridges.


8. Clean the sealing surfaces.

9. Fit a new gasket on the lower part of the intake manifold and fit the upper part.

Tightening torque 10 Nm (7 lbf ft).

10. Check the fuel rail connecting cones and replace if necessary.

11. Attach the fuel rails with clamps in their original positions.

Tightening torque 25 Nm (19 lbf ft)


12. Check the condition of the fuel return hoses and joints and replace if necessary.

13. Connect the fuel return hoses to the fuel bridges. Detach the fuel return hose from the fuel pump and connect the hose to 30 14 883 Pressure/vacuum pump . Create a vacuum of 750 mbar and wait 1 minute. Check that the pointer on the tool has not moved.

If there is found to be a leak, the fuel bridges must be examined individually. Connect the pressure/vacuum pump to the return fuel connection (not to the return hose) on each fuel bridge. If the fuel bridges are OK, check the return fuel hoses and T-pieces. The hoses should be pliable and exhibit no cracks or other damage. If there are signs of leakage, change all fuel return hoses and T-pieces. If a fuel bridges leaks, remove it, change the seal and refit the bridge. Check for leakage once again.

14. Fit the EGR valve and the throttle body.

Tightening torque, throttle body: 10 Nm (7 lbf ft)


15. Fit the wiring harness duct to the engine. Plug in the EGR valve.

16. Secure the wiring harness as it was previously.

17. Refit the hose on the intake manifold.

18. Fit the camshaft, refer to Camshaft