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Cylinder head in car, A19DTR

Cylinder head in car, A19DTR

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 the engine cover, insulation and battery cover. Detach the negative battery cable.

2. Remove turbocharger with exhaust manifold, Z19DTR

3. Remove the upper turbo oil delivery pipe (B). Plug the turbo connection.


4. Remove the coolant hose (D) from the cylinder head.

5. 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.


6. Remove Injector (206), Z19DTR .

7. Remove the Battery cover, lower section .

8. Remove the connector (A).


9. Remove the connector (B).

10. Remove the vacuum pump quick coupling (A), the hose (B) to the vacuum tank and the solenoid valve hoses (C) to the vacuum tank. Remember their locations.


11. Remove the connector for the temp sensor (E) and throttle body (F), and remove the clip (G).


12. Remove (A) the cable duct screws and lifting eye screw (B).


13. Remove the fuel pressure sensor connector (A).


14. Remove the glow plug connector (B).

15. Remove the intake air sensor connector (D).

16. Remove clip (E), move the engine coil to one side.

17. Remove the hose clip to the crankcase ventilation pipe (F). Lift off the pipe.

18. Remove the fuel delivery pipe (A) between the pump and the fuel rail.


19. Remove the fuel rail (B).

20. Remove the return fuel collector screws (C) and move the return fuel collector to one side.

21. Remove the coolant pipe quick coupling (A).


22. Remove the oil trap screws (B) and carefully bend out the oil trap so that its lower mounting comes free.

23. Remove the connector (A) for the actuator, combustion circulation.


24. Remove the breather hose (A) from the thermostat housing, move the hose to one side.


25. Remove the turbocharger delivery hose (B) from the pipe and throttle body.

26. Remove the quick coupling (C) for the rear EGR water port. Place a receptacle under the engine to collect the coolant.

27. Remove the quick coupling (D) to the front EGR water port.

28. Remove the thermostat housing coolant hose (E).

29. Remove the bolt (A) between the fuel pump bracket and cylinder head, screw out the spacer bolt (B) a few turns.


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

31. Remove the cylinder head by undoing the bolts in the illustrated order.


32. Ask an assistant to help you, and carefully lift off the cylinder head, making sure that the lower oil trap mounting comes free.

Important

Do not confuse the engine block guide sleeves with the camshaft guide sleeves.



To fit


1. Clean the bolt holes in the cylinder block.

2. Clean away any gasket remains from the cylinder head and cylinder block sealing surfaces.

3. Check the flatness of the cylinder head and cylinder block with a steel rule and inspect for damage to the sealing surfaces.

Important

Do not confuse the engine block guide sleeves with the camshaft guide sleeves.


4. Place the guide sleeves (A) on the engine block.


5. Fit a new gasket with the same thickness (B) as the old one.

6. Fit a new gasket to the exhaust manifold.

7. 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.

8. 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°


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

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


Note

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



11. 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).


12. Screw in the spacer sleeve (B) against the cylinder head and fit the bolt (A).

13. Fit turbocharger with exhaust manifold, Z19DTR

14. Fit the thermostat housing coolant hose (E).


15. Fit the quick coupling (D) for the front EGR water port.

16. Fit the quick coupling (C) to the rear EGR water port.

17. Fit the turbocharger delivery hose (B) to the pipe and throttle body.

18. Fit the breather hose (A) to the thermostat housing.

19. Fit the connector (A) to the actuator, combustion circulation.


20. Remove the oil trap screws (B) and carefully bend out the oil trap so that its lower mounting comes free.


21. Remove the coolant pipe quick coupling (A).

22. Fit the return fuel collector bolts (C).


23. Fit the fuel rail (B).

24. Fit the fuel delivery pipe (A) between the pump and the fuel rail.

25. Fit the hose clip (F) to the crankcase ventilation pipe.


26. Fit the clip (E) and move the engine coil back.

27. Fit the intake air sensor connector (D).

28. Fit the glow plug connector (B).

29. Fit the fuel pressure sensor connector (A).

30. Fit the cable duct screws (A) and lifting eye (B) screw.


31. Fit the following:

• Temperature sensor connector (E).


• Throttle body connector (F)

• Clip (G)

32. Fit the vacuum pump quick coupling (A), the hose (B) to the vacuum tank and the solenoid valve hoses (C) to the vacuum tank. Fix the hoses.


33. Fit the coolant hose (D) to the cylinder head.


34. Replace the gaskets and fit the upper turbo oil delivery pipe (B).

35. Fit the connector (B).


36. Fit the connector (A).

37. Fit the Battery cover, lower section .

38. Raise the car.

39. Fit Injector (206), Z19DTR .

40. Fit Timing belt in-car, Z19DTR .

Important

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.


41. Lower the car.

42. Test pressurise, see Cooling system, pressure testing , top up with coolant, see Filling and bleeding the cooling system, Z19DTR .

43. Replace the engine oil and filter, see Oil change, Z19DTR , Oil filter, Z19DTR

44. Reconnect the negative battery cable.

45. Remove the wing covers and restore car electrical functions, see After disconnecting the battery .

46. Connect an exhaust hose and start the engine. Check there are no leaks. Connect the diagnostic tool and clear any DTCs.

47. Fit the engine insulation and upper engine cover.