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Camshaft housing

Camshaft housing

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 situ) .

2. Remove EGR solenoid valve (606), Z19.

3. Detach the upper mounting of the turbocharger delivery pipe.


4. Detach the brake servo hose from the vacuum pump and move it aside.


5. Detach the vacuum hoses from the pump and turbo control valve. Detach the vacuum pipes from the camshaft housing and oil trap bracket.

6. Detach the crankcase ventilation hose from the cylinder head.

7. Remove the cable duct retaining bolts.

8. Unplug the following connectors:

8.a. Camshaft position sensor (555).


8.b. Injectors (206).

8.c. Fuel pressure sensor (653).

8.d. Fuel pressure solenoid valve (652a).

9. Move the engine wiring harness aside.

10. Detach the fuel delivery pipe between the pump and fuel rail.

Important

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

If new injectors are to be fitted, read the identification code on the top and check that they are suitable for the engine control module in question.



11. Remove the Injector (206) .

12. Detach the fuel rail and move it aside.


13. Loosen and remove the camshaft shaft housing and the guide sleeves. Remove in alternating order as illustrated.



To fit


1. Clean away any gasket residue from the sealing surfaces of the cylinder head and camshaft housing.

2. Fit the guide sleeves and position a new gasket on the cylinder head.

Important

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



3. Fit the camshaft housing, tightening the bolts alternatingly. Check that the guide sleeves are properly positioned in the camshaft housing.

Tightening torque: 25 Nm (15 lbf ft)


4. Fit the fuel rail.


5. Fit the Injector (206).


6. Attach the fuel delivery pipe between the pump and fuel rail.

Tightening torque: 25 Nm (18 lbf ft)

7. Plug in the following connectors:

7.a. Camshaft position sensor (555).


7.b. Injectors (206).

7.c. Fuel pressure sensor (653).

7.d. Fuel pressure solenoid valve (652a).

8. Fit the cable duct retaining bolts and secure the wiring harness.

9. Attach the crankcase ventilation hose to the cylinder head.


10. Attach the vacuum pipes to the camshaft housing and oil trap bracket. Attach the hoses to the pump and turbo pressure valve.

11. Attach the brake servo hose to the vacuum pump.

12. Fit the mounting of the turbocharger intake manifold.


13. Fit EGR solenoid valve (606), Z19 .

14. Fit Timing belt (in situ) .