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PRE-RELEASE

Cylinder head in car, Z19DTR

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

2. Remove Turbocharger with exhaust manifold, Z19DTR

3. Remove the oil delivery pipe from the upper turbocharger (B). Plug the connection on the turbocharger.


4. Remove the radiator 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. Unplug the connector (A).


9. Remove the connector (B).

10. Remove the vacuum pump's quick coupling (A), the vacuum tank hose (B ) and the hoses from the solenoid valves to the vacuum tank (C). Make a note of how they are fitted.


11. Unplug the connectors to the solenoid valve (D), the temperature sensor (E) and the throttle body (F). Remove the clip (G).


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


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


14. Unplug the glow plug connector (B).

15. Remove the glow plug (C).

16. Unplug the intake air sensor connector (D).

17. Remove the clips (E), move aside the engine wiring harness.

18. Remove the hose clip from the crankcase ventilation pipe (F). Remove the pipe.

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


20. Remove the fuel rail (B).

21. Remove the bolts from the return fuel collector (C) and push the collector out of the way.

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


23. Remove the oil trap bolts (B) and carefully twist out the oil trap so that its lower mounting disengages.

24. Unplug the connector to the combustion circulation actuator (A).


25. Unplug the EGR valve connector (B).

26. Remove the breather hose (A) from the thermostat housing and bend aside the hose.


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

28. Remove the quick coupling (C) to the rear EGR water spigot. Position a water receptacle under the engine to collect the coolant.

29. Remove the quick coupling (D) of the front EGR water spigot.

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

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


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

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


34. With the help of an assistant, carefully lift off the cylinder head; ensure that the lower mounting of the oil trap disengages.

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. With the help of an assistant, fit the cylinder head onto the cylinder block. Bend back the oil trap so that its lower mounting engages 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 The turbocharger with exhaust manifold, Z19DTR

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


15. Assemble the quick coupling (D) of the front EGR water spigot.

16. Assemble the quick coupling (D) of the rear EGR water spigot.

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

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

19. Plug in the EGR valve connector (B).

20. Plug in the connector (A) to the combustion circulation actuator.


21. Remove the oil trap bolts (B) and carefully twist out the oil trap so that its lower mounting disengages.


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

23. Fit the bolts of the return fuel collector (C).


24. Fit the fuel rail (B).

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

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


27. Fit the clips (E) and reposition the cable harness.

28. Plug in the intake air sensor connector (D).

29. Fit the glow plug (C).

Tightening torque 10 Nm (7 lbf ft)

30. Plug in the glow plug connector (B).

31. Plug in the fuel pressure sensor connector (A).

32. Fit the cable duct bolts (A) and the lifting eye bolts (B).


33. Fit the following:

• The solenoid valve connector (D)


• The temperature sensor connector (E)

• The throttle body connector (F)

• The clips (G)

34. Fit the vacuum pump's quick coupling (A), the vacuum tank hose (B ) and the hoses from the solenoid valves to the vacuum tank (C).


35. Attach the coolant hose (D) to the cylinder head.


36. Replace the gaskets and fit the upper turbocharger oil delivery pipe (B).

37. Plug in the connector (B).


38. Plug in the connector (A).

39. Fit the Battery cover, lower section .

40. Raise the car.

41. Fit Injector (206), Z19DTR .

42. 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.


43. Lower the car.

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

45. Change the engine oil and filter, see Oil change, Z19DTR , Oil filter, Z19DTR

46. Reconnect the negative battery cable.

47. Remove the wing covers and restore car electrical functions, see Procedure after reconnecting the battery .

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

49. Fit the engine insulation and upper engine cover.


PRE-RELEASE