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Tappets

Tappets

To remove


1. Remove the camshaft. Refer to Camshaft.


2. Mop up the oil from the cylinder head.

3. Disconnect the turbocharger delivery pipe and hose from the throttle body and move it aside.

4. Unplug the pressure/temp. sensor connector.

5. Remove the throttle body.

6. Unplug the connector and remove the EGR valve from the intake manifold.

7. Place a receptacle under the car to catch any fuel spills. Remove the fuel return hoses.


8. Make a note of the position of the fuel distribution pipes and clamps and mark the pipes.

9. Remove the fuel distribution pipes (if necessary, the pipe's clamps can be dismantled).

10. Remove the upper part of the intake manifold and seal the intakes.


11. Remove the bolts securing the fuel bridges. Lift and withdraw the fuel bridges from the cylinder head.

12. Remove the valve bridges.

13. Lift up the tappets with 83 91 401 Magnetic tool .

14. Remove the seals from connections between the injectors and fuel bridges.


To fit


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

2. Fit new seals to the connections between the injectors and fuel bridges.


3. Lubricate the tappets with engine oil and insert them into the cylinder head.

4. Blow the bolt holes for the fuel bridges clean.

5. Fit new O-rings to the fuel bridges. Lubricate the O-rings with acid-free vaseline and carefully insert the fuel bridges into the cylinder head.

6. Tighten the bolts securing the fuel bridges.

Tightening torque 5 Nm + 360°(4 lbf ft + 360°)

7. Fit the valve bridges.

Important

Make a note of the position of the valve bridges. The valve bridges are marked on the side facing the fuel bridges.


8. Clean the sealing surfaces.

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

Tightening torque 10 Nm (7 lbf ft)

10. Check the fuel distribution pipes' connecting cones and replace if necessary.

11. Fit the fuel distribution pipes to their original positions with the clamps.

Tightening torque 25 Nm (19 lbf ft)


12. Check the condition of the fuel return pipes and connectors and change if necessary.

13. Connect the fuel return hoses to the fuel bridges. Undo the fuel return hose connection at the fuel pump and connect 30 14 883 Pressure/vacuum pump and 83 93 514 Charge pressure gauge to the hose. Pump 750 mbar of negative pressure and wait 1 minute. Check that the pointer on the tool has not moved.

If you detect a leak, check each fuel bridge in turn. Connect the pressure/vacuum pump in turn to the fuel return connection on each fuel bridge, not the return hose. If the fuel bridges are OK, check the fuel return hoses and the T-piece.

The hoses should be supple and not cracked or damaged in any way. If there are indications of a leak, change all the fuel return hoses and T-pieces. If the leak originates in a fuel bridge, remove the bridge, change the seal and refit the bridge. Recheck the system for leaks.

14. Fit the EGR valve using a new O-ring.

Tightening torque 10 Nm (7 lbf ft)

15. Plug in the EGR valve.


16. Fit the throttle body using a new gasket.

Tightening torque 10 Nm (7 lbf ft)

17. Fit the pressure/temp. sensor connector on the throttle body.

18. Connect the turbocharger deliver pipe and hose to the throttle body.

19. Fit the Camshaft .