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PRE-RELEASE

Valve timing, exhaust camshaft check, Z19DTR

Valve timing, exhaust camshaft check, Z19DTR

To remove


1. Protect the wings with covers.

2. Disconnect the negative cable from the battery.

3. Raise the car.

4. Remove the front right wheel.

5. Remove the right wing liner (A). F421R465

6. CV: Remove Chassis reinforcement, front subframe, CV, diesel .

7. Remove the lower engine cover (A). F421R454

8. Remove the Spoiler shield, front

9. Undo the hose clip (A) of the turbocharger intake manifold. Illustration.

10. Fit 83 96 145 Centring fixture, subframe - engine on the engine subframe and 83 96 368 Supplementary kit to centring fixture and 32 025 007 Mounting fixture . Use only the front mounting fixture applied against the A/C compressor bracket. Take the strain off the engine bracket by adjusting the fixture. F421R401

11. Relieve the belt tensioner (A) and lock it with 87 92 335 Lock pin (B). Remove the drive belt (C) for the auxiliaries. F421R466

12. Remove the crankshaft pulley.

Important

The centre bolt of the belt pulley is not to be slackened.


13. Remove the idler pulley centre bolt on the lower timing cover. Use, for example, 2 screwdrivers to carefully prise off from two directions.

14. Lower the car.

15. Remove the upper engine cover and insulation. Illustration.

16. Detach the mass air flow sensor's connector (A), wiring harness (B), hose (C) and the air filter housing's cover (D) and filter. Plug the intake manifold with a clean cloth. Illustration.

17. Remove the air filter housing.

18. Remove the right engine mounting (A). Illustration

19. Remove the bolts (A) of the crankcase ventilation pipe and detach the electrical connection of the camshaft position sensor (B)

20. Undo the mounting (C) and bolts (D) from the turbocharger delivery pipe. Keep track of the O-rings.

21. Detach the turbocharger intake manifold from the timing cover

• 1 bolt (A) Illustration.

22. Remove the upper timing cover.

• Press the turbocharger intake manifold forward.

• 1 cable clip (A)

• 7 bolts. Use an Allen key with ball for the front bolt (B). Illustration.

23. Remove the lower timing cover.

• 5 bolts (A) Illustration.

Note

Take note of the bolt locations.


24. Zero the engine by removing the plug and fitting 32 025 008 Camshaft fixing tool. (A). Illustration.

25. Turn round the engine until the tool engages and locks the exhaust camshaft.

26. Raise the car.

27. Remove the bolt from the oil pump and fit 32 025 009 Crankshaft fixing tool (B) to the crankshaft sprocket.

28. If the guide pin of the crankshaft sprocket goes into the hole of the tool, the camshaft setting is correct. If the setting is not correct, it must be adjusted. See Timing belt in-car, Z19DTR .

29. Remove the tool and fit the plug on the camshaft cover and the bolt to the oil pump.

30. Fit the lower timing cover (A)

• 3 upper bolts - 50 Nm

Tightening torque 50 Nm (37 lbf ft)

• 2 lower bolts - 25 Nm

Tightening torque 25 Nm (18 lbf ft)

31. Fit the upper timing cover. Press the turbocharger intake manifold forward.

• 1 cable clip (A)

• 7 bolts. Use an Allen key with ball for the front bolt (B). Illustration

32. Fit the mounting (C) and bolts (D) of the turbocharger delivery pipe. Use new O-rings. Illustration.

33. Fit the bolts (A) of the crankcase ventilation pipe and attach the electrical connection of the camshaft position sensor (B)

34. Fit the right engine mounting (A). Illustration.

Tightening torque to engine 50 Nm (137 lbf ft)

Tightening torque to body 40 Nm + 60° (30 lbf ft + 60°).

35. Fit the air filter housing.

• Remove the cloth from the turbocharger intake manifold.

• Fit the filter.

• Fit the air filter housing

• Fit the cover (D).

• Attach the hose (C).

• Attach the wiring harness (B).

• Fit the mass air flow sensor connector (A).

36. Fit the insulation and the upper engine cover.

37. Raise the car.

38. Fit the idler pulley centre bolt on the lower timing cover.

Tightening torque 25 Nm (18 lbf ft)

39. Fit the crankshaft pulley. F421R409

Tightening torque 25 Nm (18 lbf ft)

Note

Make sure the guide pin is in its recess.


40. Relieve tension in the belt tensioner (A), fit the drive belt (C) and remove the lock pin (B). F421R466

41. Remove the engine fixing tool from the subframe. F421R401

42. Tighten the hose clip (A) of the turbocharger intake manifold. Illustration.

43. Fit the Spoiler shield, front

44. Fit the lower engine cover (A). F421R454

45. CV: Fit Chassis reinforcement, front subframe, CV, diesel

46. Fit the right wing liner. (A) F421R465

47. Fit the front right wheel. See Wheels .

48. Lower the car.

49. Fit the battery negative cable.

50. Carry out Procedures after reconnecting the battery .

51. Start the engine and turn it off.

52. Remove the wing cover.


PRE-RELEASE