Cylinder head in car, Z19DTH
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Cylinder head in car, Z19DTH
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Warning
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The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:
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• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.
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• Absolutely No Smoking!
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• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.
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• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
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• Wear protective goggles.
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Warning
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Diesel under high pressure! So wait for at least one minute after switching off the engine before starting work in the fuel system. Diesel fumes are explosive and can cause severe burn injuries.
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Important
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Always use wing covers when working in the engine bay.
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1.
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Remove the engine cover, insulation and battery cover. Detach the negative battery cable.
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Warning
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The cooling system is under pressure. Hot coolant and steam can escape.
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- Open the cap slowly to release the pressure.
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- Carelessness can cause eye and burn injuries
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2.
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Undo the expansion tank cap (B) to release pressure and then retighten the cap.
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4.
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Remove the front right wheel.
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5.
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Remove the right wing liner (A).
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6.
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Remove the lower engine cover (A).
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7.
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Undo the right-hand part of the front lower cover and bend down.
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8.
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Place a receptacle under the radiator, connect a hose (A) to the radiator (B) and drain the coolant. Close the cock and fit the cover.
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9.
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Remove the vacuum hose from the diaphragm box (A) and remove the temperature sensor (B) from the catalytic converter.
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10.
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Slightly undo the lower mounting (A) of the front catalytic converter, and remove the screws from the catalytic converter mounting (B).
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12.
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Undo the front exhaust pipe from the catalytic converter (A) and gearbox (B). Lower the pipe on the centring tool.
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13.
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Undo the turbo return oil pipe (A) and the pressure oil pipe (B) from the engine block.
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14.
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Relieve the belt tensioner (B) and lock it with
87 92 335 Lock pin
(A). Remove the drive belt (C) for the auxiliaries.
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15.
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Remove the crankshaft pulley.
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Important
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The centre bolt of the belt pulley is not to be slackened.
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16.
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Remove the idler wheel centre bolt on the lower timing cover. Use e.g. 2 screwdrivers to carefully prise from two directions.
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18.
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Remove the turbocharger delivery hose from the pipe and throttle body (A) and the upper coolant hose (B) from the thermostat.
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19.
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Remove the air exhaust hose from the radiator (A).
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20.
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Remove the air exhaust hose from the cylinder head (B).
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21.
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Remove the electrical connection from the fan cowling (C).
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22.
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Remove the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold (D).
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23.
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Remove the coolant level sensor connector and lift away the reservoir (E).
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24.
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Detach the mass air flow sensor's connector (A), wiring harness (B), hose (C), the air filter housing's cover (D) and filter. Plug the intake manifold with a clean cloth.
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25.
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Remove the AC pressure sensor connector.
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26.
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Remove the turbocharger delivery pipe and hose (A) from the turbocharger outlet. Plug the connections.
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27.
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Remove the screw (B) holding the dipstick tube.
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28.
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Remove the crankcase ventilation hose (C) from the pipe.
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29.
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Remove the turbocharger intake pipe (D). Plug the connections.
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30.
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Remove the right engine mounting (A).
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31.
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Remove the upper timing cover (B).
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32.
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Remove the lower coolant hose (A) from the coolant pipe.
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33.
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Remove the coolant hose (B) from the coolant pipe.
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34.
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Remove the vacuum hose (C).
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35.
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Undo the bolt holding the turbocharger intake pipe upper retaining bracket slightly.
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36.
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Remove the lower timing cover (A).
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37.
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Undo the wiring harness from the crankcase ventilation pipe (A), and remove the bolts holding the pipe (B) and bend it aside.
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38.
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Remove the plug on the camshaft housing and fit the 32 025 008 Camshaft fixing tool (C).
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39.
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Turn round the engine until the tool engages and locks the exhaust camshaft.
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40.
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Relieve tension in the belt tensioner (A) and remove the camshaft belt (B). If refitting the old belt, mark the direction of rotation.
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41.
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Remove the brake servo hose from the vacuum pump (A) and bend aside.
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42.
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Undo the crankcase ventilation hose from the cylinder head (B).
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43.
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Remove the coolant hoses from the thermostat housing and EGR cooler (A). Place a receptacle under the engine to collect the coolant.
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44.
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Remove the nuts and bolts (A) holding the oil trap bracket and bend it aside.
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45.
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Remove the combustion circulation actuator (A), carefully prise the control arm (B) loose from the ball joint.
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46.
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Remove the following connectors:
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A/C compressor connector (A).
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Front temperature sensor (602) (B).
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Camshaft position sensor (555) (C).
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Sensor, fuel pressure (653) (E).
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Fuel pressure solenoid valve (652a) (F).
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Throttle body actuator (604) (G).
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Sensor, intake air (688) (H).
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Glow plug connector (I).
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Coolant temperature sensor (202) (J).
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EGR valve connector (K).
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Remove the cable duct retaining screws (L).
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47.
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Fold away the engine wiring harness.
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48.
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Remove the fuel return hoses (A) from the return fuel collector.
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49.
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Remove the fuel delivery pipe (B) between the pump and the fuel rail.
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Important
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If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.
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51.
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Remove the fuel rail (A) and the hose (B).
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52.
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Remove the bolt (A) between the fuel pump bracket and cylinder head, screw out the spacer bolt (B) a few turns.
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53.
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Undo and remove the camshaft housing (C) and guide sleeves. Loosen bolts alternately as illustrated.
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54.
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Remove the cylinder head by undoing the bolts in the illustrated order.
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55.
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Carefully lift off the cylinder head.
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Important
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Do not confuse the engine block guide sleeves with the camshaft guide sleeves.
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56.
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Remove the engine block guide sleeves.
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1.
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Clean the bolt holes in the cylinder block.
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2.
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Clean away any gasket remains from the cylinder head and cylinder block sealing surfaces.
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3.
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Check the flatness of the cylinder head and cylinder block with a steel rule and inspect for damage to the sealing surfaces.
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Important
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Do not confuse the engine block guide sleeves with the camshaft guide sleeves.
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4.
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Place the guide sleeves (A) on the engine block.
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5.
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Fit a new gasket with the same thickness (B) as the old one.
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6.
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Ask an assistant to help you, and fit the cylinder head to the cylinder block. Bend back the oil trap so that its lower mounting is against the engine block.
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7.
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Tighten the cylinder head bolts in the illustrated order.
Tightening torque
Stage I 65 Nm (48 lbf ft)
Stage II +90°
Stage III +90°
Stage IV +90°
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8.
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Clean the cylinder head and camshaft housing sealing surfaces from any gasket residue.
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9.
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Fit the guide sleeves (A) and fit a new gasket onto the cylinder head.
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Note
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Check that all the rocker arms are positioned correctly on the valve stems.
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10.
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Fit the camshaft housing (C), tighten the bolts alternately. Make sure the guide sleeves are positioned correctly in the camshaft housing.
Tightening torque 25 Nm (18 lbf ft)
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11.
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Screw in the spacer sleeve (B) against the cylinder head and fit the bolt (A).
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12.
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Fit the fuel rail (A) and the hose (B).
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14.
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Fit the fuel delivery pipe between the pump and the fuel rail.
Tightening torque 25 Nm (18 lbf ft)
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15.
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Fit the fuel return hose (A) to the return fuel collector.
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16.
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Fold the engine wiring harness back in place and fit the following connectors:
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A/C compressor connector (A).
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Front temperature sensor (602) (B).
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Camshaft position sensor (555) (C).
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Sensor, fuel pressure (653) (E).
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Fuel pressure solenoid valve (652a) (F).
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Throttle body actuator (604) (G).
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Sensor, intake air (688) (H).
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Glow plug connector (I).
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Coolant temperature sensor (202) (J).
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EGR valve connector (K).
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17.
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Fit the cable duct retaining screws and fix the wiring harness.
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18.
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Fit the swirl throttle actuator (A). Press the control arm (B) onto the ball joint. Use a suitable pair of pliers.
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19.
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Bend the oil trap bracket back in place and fit the nuts and bolts (A).
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20.
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Fit the coolant hoses on the thermostat housing and the EGR cooler (A).
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21.
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Fit the crankcase ventilation hose (B) onto the cylinder head.
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22.
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Fit the brake servo hose (A) to the vacuum pump. Secure the hose.
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23.
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Fit the timing belt so that the marks on the belt align with the marks on the crankshaft, exhaust camshaft and fuel pump sprocket (A).
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26.
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Adjust so that the belt tensioner arrow is right in front of the mark by pressing the setting lever in the direction of the arrow. Tighten the belt tensioner using a large screwdriver and an M8 bolt for support.
Tightening torque 25 Nm (18 lbf ft)
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27.
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Remove the adjustment tool and turn the crankshaft 2 turns.
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29.
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Remove the tool and fit the plug on the camshaft cover and the bolt to the oil pump.
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30.
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Fit the crankcase ventilation pipe (B) and secure the wiring harness (A) to the pipe.
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31.
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Fit the lower timing cover (A).
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32.
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Tighten the bolt on the turbocharger intake pipe bracket.
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33.
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Connect the vacuum hose (C).
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34.
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Fit the coolant hose to the coolant pipe (B).
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35.
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Fit the lower coolant hose (A) to the coolant pipe.
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36.
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Fit the upper timing cover (B).
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37.
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Fit the right engine mounting (A).
Tightening torque on engine, 50 Nm (137 lbf ft)
Tightening torque to body 40 Nm + 60° (30 lbf ft + 60°).
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38.
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Fit the turbocharger intake pipe (D).
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39.
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Fit the crankcase ventilation hose (C) to the pipe.
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40.
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Fit the screw (B) holding the dipstick tube.
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Important
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To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
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41.
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Remove the plugs and fit the turbocharger delivery pipe and hose (A) to the turbocharger outlet.
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42.
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Remove the cloth from the turbocharger intake manifold. Fit the filter, air filter housing cover (D), hose (C), wiring harness (B) and mass air flow sensor connector (A).
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43.
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Fit the AC pressure sensor connector.
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44.
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Fit the coolant tank onto the bulkhead and fit the level sensor connector (E).
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45.
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Fit the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold (D).
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46.
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Fit the electrical connection on the fan cowling (C).
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47.
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Fit the air exhaust hose onto the cylinder head (B).
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48.
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Fit the air exhaust hose onto the radiator (A).
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49.
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Fit the upper coolant hose (B) to the thermostat housing, and the turbocharger delivery hose to the turbocharger delivery pipe and throttle body (A).
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Important
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To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
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51.
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Fit the crankshaft pulley.
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Note
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Make sure the guide pin is in its recess.
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Tightening torque 25 Nm (18 lbf ft)
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52.
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Fit the idler wheel.
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53.
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Relieve tension in the belt tensioner (B), fit the drive belt (C) and remove the lock pin (A).
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54.
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Fit the turbo return oil pipe (A) and the oil delivery pipe (B) to the engine block.
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55.
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Lift up and fit the front exhaust pipe to the catalytic converter (A) and the gearbox (B) with a new gasket.
Tightening torque 25 Nm (18 lbf ft)
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56.
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Remove the engine fixing tool from the subframe. Fit the bolt to the A/C compressor bracket.
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57.
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Tighten the lower mounting (A) of the front catalytic converter, and fit the screws at the catalytic converter mounting (B).
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58.
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Fit the vacuum hose to the diaphragm box (A) and fit the temperature sensor to the catalytic converter (B).
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59.
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Fit the lower engine cover (A).
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60.
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Fit the right wing liner (A).
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64.
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Change engine oil and filter.
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65.
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Reconnect the negative battery cable.
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67.
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Connect an exhaust hose and start the engine. Check that there are no leaks.
Connect the diagnostic tool and erase any diagnostic trouble codes.
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68.
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Fit the engine insulation and upper engine cover.
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