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PRE-RELEASE

Camshaft housing, Z19DTR

Camshaft housing, 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 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.


2. Remove Injector (206), Z19DTR .

3. Detach the brake servo hose (A) from the vacuum pump, as well as the vacuum tank's suction hose (B), move aside.


4. Remove the cable duct's bolts (A) as well as the lifting eye's bolts for the intake manifold.


5. Remove the following:


• engine wiring harness clip (B)

• connector to throttle body (C),

• temperature sensor connector (D)

• solenoid valve connector (E).

Then fold aside the engine wiring harness.

6. Unplug the fuel pressure sensor connector (A) (653).


7. Remove the return fuel line (B).

8. Remove the fuel delivery pipe (C) between the pump and the fuel rail.

9. Remove the fuel rail (D).

10. Remove the upper heat shield (A) as well as the turbocharger's oil delivery pipe (B). Plug the turbocharger's connection, as well as the camshaft housing.


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



To fit


1. Clean the cylinder head and camshaft housing sealing surfaces from any gasket residue.

Important

Check that all rocker arms are positioned correctly on the valve stems.



2. Fit the guide sleeves (A) and fit a new gasket onto the cylinder head.


3. 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 (15 lbf ft).


4. Fit the turbocharger's oil delivery pipe (B) as well as the upper heat shield (A).


5. Fit the fuel rail (D).


6. Fit the fuel delivery pipe (C) between the pump and the fuel rail.

Tightening torque 25 Nm (18 lbf ft).

7. Fit the return fuel line (B).

8. Plug in the fuel pressure sensor (653) connector. (A).

9. Fold the engine wiring harness back in place and fit the following:

• Solenoid valve connector (E)


• Temperature sensor connector (D)

• Throttle body connector (C)

• Clip (B)

10. Fit the cable duct's bolts (A) as well as the lifting eye's bolts for the intake manifold.


11. Fit the vacuum tank's suction hose (B) as well as the brake servo's hose (A) to the vacuum pump.


12. Fit Injector (206), Z19DTR .

13. Remove Timing belt in-car, Z19DTR .


PRE-RELEASE