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Camshafts in-car, Z19DTR.

Camshafts in-car, Z19DTR.

Warning

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:

• 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.

• Absolutely No Smoking!

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

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

• Wear protective goggles.


To remove

Warning

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.


Important

Always use wing covers when working in the engine bay.



1. Remove Timing belt in-car, Z19DTR .

Important

If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.


2. Remove Injector (206), Z19DTR .

3. Detach the brake servo hose (A) from the vacuum pump and detach the vacuum tank suction hose (B). Move them aside.


4. Remove the cable duct bolts (A) and the lifting eye bolt to the intake manifold.


5. Remove the following:

• Engine harness clips (B)


• Throttle body connector (C)

• Temperature sensor connector (D)

• Solenoid valve connector (E) and move aside the engine harness.

6. Unplug the fuel pressure sensor connector (A) (653).


7. Detach the return fuel line (B).

8. Remove the fuel delivery pipe (D) between the pump and the fuel rail.

9. Remove the fuel rail (D).

10. Remove the upper heat shield (A) and the upper turbocharger's oil delivery pipe (B). Plug the turbocharger connection and the camshaft housing.


11. Detach the charge air hose (A) from pipe and throttle body.


12. Remove the vacuum pump (A).


13. Remove the filler pipe (B).

14. Check that 32 025 008 Fixing tool, camshaft has locked the exhaust camshaft.

Note

Undo the bolt to the intake camshaft first.


15. Undo the bolts (A) of the camshaft gears.


16. Undo the bolt (A) of the camshaft drive wheels.

17. Undo and remove the camshaft housing (C) and guide sleeves. Loosen bolts alternately as illustrated.

18. Remove the camshaft drive wheels (A).


19. Remove the camshaft gears (B).

20. Remove the exhaust camshaft sealing ring (C) with a suitable tool. Take care not to damage the sealing surface. Remove the exhaust camshaft.

21. Press out the intake camshaft and the sealing plug (D).


To fit


1. Lubricate the bearing surfaces with engine oil. Fit the camshafts.

2. Lock both camshafts with 32 025 008 Camshaft fixing tool . Make sure the tool is fitted correctly. The reference pins must snap in audibly.


3. Clean the cylinder head and camshaft housing sealing surfaces from any gasket residue.

4. Fit the guide sleeves (A) and fit a new gasket onto the cylinder head.


Important

Check that all rocker arms are positioned correctly on the valve stems.



5. Fit the camshaft housing (C), tightening the bolts alternately. Make sure the guide sleeves are positioned correctly in the camshaft housing.

Tightening torque 25 Nm (15 lbf ft).


6. Fit the camshaft gear wheels (A). The gear wheel with dogs is to be mounted onto the exhaust camshaft.

Tightening torque 120 Nm (88 lbf ft)


7. Remove the fixing tool from the intake side.

8. Fit the sealing plug (B) with a new O-ring.

9. Clean the vacuum pump and oil filler pipe sealing surfaces.

10. Clean the cylinder head and camshaft housing sealing surfaces from any gasket residue.

11. Fit the vacuum pump (A) with a new seal.

Tightening torque 9 Nm (7 lbf ft).


12. Fit the oil filler pipe (B) with a new seal.

Tightening torque 9 Nm (7 lbf ft).

13. Attach the charge air hose (A).


14. Fit the upper turbocharger's oil delivery pipe (B) and the upper heat shield (A).


15. Attach the fuel rail (A).


16. Attach the fuel delivery pipe (C) between the pump and fuel rail.

Tightening torque 25 Nm (18 lbf ft).

17. Attach the return fuel line (B).

18. Fit the fuel pressure sensor (A) connector (653).

19. Reposition the engine wiring harness and fit the following:

• Solenoid valve connector (E).


• Temperature sensor connector (D)

• Throttle body connector (C)

• Clips (B)

20. Fit the cable duct bolts (A) and the lifting eye bolt to the intake manifold.


21. Attach the vacuum tank suction hose (B) and the brake servo hose (A) to the vacuum pump.

Important

If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.



22. Fit Injector (206), Z19DTR .

23. Fit the intake camshaft sealing plug (A).


24. Lubricate the sealing ring with 90 167 353 Silicone paste . Fit the camshaft sealing ring with 32 025 050 Fitting tool, camshaft seal .

25. Fit the camshaft drive wheels (B) with new bolt. Screw in the bolt loosely so that it is pressing against the drive wheel but so the drive wheel can still be turned in relation to the exhaust camshaft. The exhaust camshaft must be locked with 32 025 008 Camshaft fixing tool .

26. Fit Timing belt in-car Z19DTR . Before removing 32 025 008 Camshaft fixing tool, tighten the bolt for the camshaft drive wheel after setting the timing belt. The drive wheel must not turn when the bolt is tightened.

Tightening torque 120 Nm (89 lbf ft).