Timing belt in car Z19DTR

/ 9-3 (9440) / 2009 / 2. Engine / 4-cylinder diesel / Basic engine / Adjustment/replacement / Timing belt in car 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).

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

7.	Remove the lower engine cover.

8.	Remove the Spoiler shield, front .

9.	Detach the hose clip of the turbocharger intake manifold.

10.

Fit 83 96 145 Centring fixture, subframe - engine - engine on to the engine subframe and 83 96 368 Supplementary kit to centring fixture , 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.

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

12.	Remove the crankshaft pulley. Important The centre bolt of the belt pulley is not to be slackened.

13.	Remove the idler wheel centre bolt on the lower timing cover. Use e.g. 2 screwdrivers to carefully prise from two directions.

14.	Lower the car.

15.	Remove the upper engine cover (A) and insulation.

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

17.	Remove the air filter housing.

18.	Remove the right engine mounting (A).

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.

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1 bolt (A)

22.	Remove the upper timing cover. Press the turbocharger intake manifold forward.

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1 cable clip

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7 bolts (B).

23.	Remove the lower timing cover (A). Note Take note of the bolt locations.

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

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

26.	Relieve tension in the belt tensioner (A) and remove the timing belt (B). If refitting the old belt, mark the direction of rotation.

27.	Replace the water pump if it is leaking coolant or if there is play or noise in the bearings.

To fit

1.	Fit the timing belt so that the marks on the belt align with the marks on the crankshaft, exhaust camshaft and fuel pump sprocket (A).

2.	Raise the car.

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

4.	Fit the belt tensioner without tightening the bolt.

5.	Adjust so that the belt tensioner arrow is right in front of the mark by pressing the setting lever in the direction of the arrow. Tighten the belt tensioner using a large screwdriver and an M8 bolt for support. Tightening torque 25 Nm (18 lbf ft)

6.	Remove the adjustment tool and turn the crankshaft 2 turns.

7.	Refit 32 025 008 Camshaft fixing tool and 32 025 009 Crankshaft fixing tool . Check that the belt is fitted correctly and that the tension roller setting arrow is in front of the mark.

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

9.	Fit the lower timing cover (A).

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3 upper bolts - 50 Nm (37 lbf ft)

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2 lower bolts - 25 Nm (18 lbf ft)

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

11.	Fit the turbocharger intake manifold to the timing cover (A).

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

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

14.	Fit the right engine mounting (A). Tightening torque on engine, 50 Nm (37 lbf ft) Tightening torque to body 40 Nm + 60° (30 lbf ft + 60°).

15.	Fit the air filter housing.

16.	Remove the cloth from the turbocharger intake manifold. Fit the filter, air filter housing cover (D), hose (C), wiring harness (B) and mass air flow sensor connector (A).

17.	Fit the insulation and the upper engine cover (A).

18.	Raise the car.

19.	Fit the idler pulley centre bolt on the lower timing cover. Tightening torque 25 Nm (18 lbf ft)

20.	Fit the crankshaft pulley. Note Make sure the guide pin is in its recess. Tightening torque 25 Nm (18 lbf ft)

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

22.	Remove the engine fixing tool from the subframe.

23.	Tighten the hose clip of the turbocharger intake manifold.

24.	Fit the Spoiler shield, front .

25.	Fit the lower engine cover (A).

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

27.	Fit the right-hand wing liner (A).

28.	Fit the front right wheel. See Wheels .

29.	Lower the car.

30.	Fit the battery negative cable.

31.	Carry out Procedures after reconnecting the battery .

32.	Start the engine and turn it off.

33.	Remove the wing cover.

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