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Camshafts (in situ)

Camshafts (in situ)

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. Undo the turbocharger delivery pipe's upper mounting slightly.


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. Detach the charge air hose from the pipe and throttle body.


14. Remove the vacuum pump.


15. Unplug the temperature sensor connector.

16. remove the oil filer port.

17. Check that 32 025 008 Camshaft fixing tool has locked the exhaust camshaft in place.

Note

Slacken the first bolt of the intake camshaft.


18. Slacken the bolts of the camshaft gear wheels.


19. Slacken the bolt of the camshaft drive wheels.

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

21. Remove the camshaft drive wheels.


22. Remove the camshaft gear wheels.

23. Remove the seal ring of the exhaust camshaft using a suitable tool. Be careful so as not to damage the sealing surface. Remove the exhaust camshaft.

24. Press out the intake camshaft and seal plug.


To fit


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

2. Lock both camshafts with 32 025 008 Camshaft fixing tool . Check that the tool is correctly fitted. The reference drifts must audibly engage.


3. Fit the camshafts' gear wheels. The gear wheel with drive lugs is to be fitted on the exhaust camshaft.

Tightening torque: 120 Nm (88 lbf ft)


4. Remove the fixing tool on the inlet side.

5. Fit the seal plug using a new O-ring.

6. Clean the sealing surfaces of the vacuum pump and oil filler port.

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

8. Fit the vacuum pump using a new seal.

Tightening torque: 9 Nm (7 lbf ft)


9. Fit the oil filler port using a new seal.

Tightening torque: 9 Nm (7 lbf ft)

10. 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.



11. 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)


12. Fit the 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.



13. Fit the Injector (206) .


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

Tightening torque: 25 Nm (18 lbf ft)

15. Plug in the following connectors:

15.a. Camshaft position sensor (555)


15.b. Injectors (206)

15.c. Fuel pressure sensor (653).

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

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

17. Attach the crankcase ventilation hoses to the cylinder head.

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


19. Tighten the mounting of the turbocharger intake manifold.


20. Fit the intake camshaft seal plug.


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

22. Fit the camshaft drive wheels using a new bolt. Tighten the bolt just enough that it lies against the drive wheel but so that the drive wheel can still be turned in relation to the exhaust camshaft. The exhaust camshaft should be locked with 32 025 008 Camshaft fixing tool .

23. Plug in the temperature sensor connector.


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

25. Attach the charge air hose.

Tightening torque 4 Nm (3 lbf ft)

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

27. Fit Timing belt (in situ) . Before removing 32 025 008 Camshaft fixing tool , tighten the bolt of the camshaft drive wheels once the timing belt has been adjusted. The drive wheel must not turn when the bolt is tightened.

Tightening torque: 120 Nm (89 lbf ft)