PRE-RELEASE
Tappets
| Tappets |
| To remove |
| 1. |
Remove the camshaft. Refer to
Camshaft.
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| 2. |
Mop up the oil from the cylinder head.
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| 3. |
Disconnect the turbocharger delivery pipe and hose from the throttle body and move it aside.
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| 4. |
Unplug the pressure/temp. sensor connector.
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| 5. |
Remove the throttle body.
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| 6. |
Unplug the connector and remove the EGR valve from the intake manifold.
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| 7. |
Place a receptacle under the car to catch any fuel spills. Remove the fuel return hoses.
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| 8. |
Make a note of the position of the fuel distribution pipes and clamps and mark the pipes.
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| 9. |
Remove the fuel distribution pipes (if necessary, the pipe's clamps can be dismantled).
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| 10. |
Remove the upper part of the intake manifold and seal the intakes.
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| 11. |
Remove the bolts securing the fuel bridges. Lift and withdraw the fuel bridges from the cylinder head.
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| 12. |
Remove the valve bridges.
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| 13. |
Lift up the tappets with
83 91 401 Magnetic tool
.
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| 14. |
Remove the seals from connections between the injectors and fuel bridges.
|
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| To fit |
| 1. |
Clean all the removed parts and check for wear. Change if necessary.
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| 2. |
Fit new seals to the connections between the injectors and fuel bridges.
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| 3. |
Lubricate the tappets with engine oil and insert them into the cylinder head.
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| 4. |
Blow the bolt holes for the fuel bridges clean.
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| 5. |
Fit new O-rings to the fuel bridges. Lubricate the O-rings with acid-free vaseline and carefully insert the fuel bridges into the cylinder head.
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| 6. |
Tighten the bolts securing the fuel bridges.
Tightening torque 5 Nm + 360°(4 lbf ft + 360°) |
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| 7. |
Fit the valve bridges.
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| 8. |
Clean the sealing surfaces.
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| 9. |
Place a new gasket on the lower part of the intake manifold and fit the upper part of the intake manifold.
Tightening torque 10 Nm (7 lbf ft) |
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| 10. |
Check the fuel distribution pipes' connecting cones and replace if necessary.
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| 11. |
Fit the fuel distribution pipes to their original positions with the clamps.
Tightening torque 25 Nm (19 lbf ft) 
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| 12. |
Check the condition of the fuel return pipes and connectors and change if necessary.
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| 13. |
Connect the fuel return hoses to the fuel bridges. Undo the fuel return hose connection at the fuel pump and connect
30 14 883 Pressure/vacuum pump
and
83 93 514 Charge pressure gauge
to the hose. Pump 750 mbar of negative pressure and wait 1 minute. Check that the pointer on the tool has not moved.
If you detect a leak, check each fuel bridge in turn. Connect the pressure/vacuum pump in turn to the fuel return connection on each fuel bridge, not the return hose. If the fuel bridges are OK, check the fuel return hoses and the T-piece. The hoses should be supple and not cracked or damaged in any way. If there are indications of a leak, change all the fuel return hoses and T-pieces. If the leak originates in a fuel bridge, remove the bridge, change the seal and refit the bridge. Recheck the system for leaks. |
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| 14. |
Fit the EGR valve using a new O-ring.
Tightening torque 10 Nm (7 lbf ft) |
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| 15. |
Plug in the EGR valve.
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| 16. |
Fit the throttle body using a new gasket.
Tightening torque 10 Nm (7 lbf ft) |
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| 17. |
Fit the pressure/temp. sensor connector on the throttle body.
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| 18. |
Connect the turbocharger deliver pipe and hose to the throttle body.
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| 19. |
Fit the
Camshaft
.
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