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PRE-RELEASE

Tappets

Tappets

To remove

Warning

Removal of the fuel rail involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:

• Make sure a class BE fire extinguisher is close to hand! Consider the risk of sparking, e.g. when breaking circuits, short-circuits etc.

• Absolutely No Smoking!

• Ensure that there is a good exchange of air. If approved ventilation for the extraction of fuel fumes is available, this should be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.



1. Remove the camshaft, see Camshaft.


2. Remove any oil found on top of the cylinder head.

3. Remove the turbocharger delivery pipe with hose from the throttle body and move it out of the way.

4. Unplug the pressure/temperature sensor and disconnect the ground cable.

5. Remove the throttle body.

6. Unplug the EGR valve connector and remove the EGR valve from the intake manifold.

7. Place a receptacle under the car to collect any spilled fuel. Remove the fuel return hoses.


8. Make a note of the position of the fuel distribution pipes and their clips, mark the pipes.

9. Remove the fuel rail (remove the rail clips if necessary).

10. Remove the upper part of the intake manifold and plug the passageways.

11. Remove the retaining bolts for the fuel bridges, lift and pull out the fuel bridges from the cylinder head.


12. Remove the valve bridges.

Important

Note the position of the valve bridges. The marks on the valve bridges are on the side facing the fuel bridges.


13. Lift up the tappets with 83 91 401 Magnetic tool .

14. Remove the seals from the injector connections in the fuel bridges.


To fit


1. Clean all dismantled parts and inspect for wear. Change as necessary.

2. Fit the seals from the injector connections in the fuel bridges.


3. Lubricate the tappets with engine oil and position them in the cylinder head.

4. Blow clean the holes for the fuel bridge retaining bolts.

5. Fit the new O-rings onto the fuel bridges, lubricate the O-rings with non-acidic Vaseline and carefully push them into the cylinder head.

6. Tighten the fuel bridge bolts.

Tightening torque: 5 Nm + 360°(4 lbf ft + 360°)

7. Fit the valve bridges.

Important

Note how the valve bridges are fitted. The markings are on the side of the valve bridges facing the fuel bridges.


8. Clean the sealing surfaces.

9. Place a new gasket on the lower part of the intake manifold and fit the upper part.

Tightening torque: 10 Nm (7 lbf ft).

10. Inspect the tapered fuel rail connections and replace as necessary.

11. Connect the fuel rail with clips in their original positions.

Tightening torque: 25 Nm (19 lbf ft).


12. Check the condition of the fuel return hoses and joints and change as necessary.

13. Connect the fuel return hoses to the fuel bridges. Loosen the fuel return connection from the fuel pump and connect 30 14 883 Pressure/vacuum pump . Pump up a vacuum of 750 mbar and wait for 1 minute. Check that the indicator on the tool has not moved.

If there is a leak, the fuel bridges must be inspected individually. Connect a pressure/vacuum pump to each fuel bridge return fuel line, do not use the existing return hose. If the fuel bridges are free from faults, inspect the return fuel hoses with T-pieces.

The hoses must be supple and not be cracked or damaged in any other way. If there are signs of leaks, change all the fuel return hoses with T-pieces. If the fuel bridge is leaking, remove it, change the seal and fit the fuel bridge. Check for leaks again.

14. Fit the EGR valve with a new O-ring.

Tightening torque: 10 Nm (7 lbf ft)


15. Plug in the EGR valve connector.

16. Fit the throttle body with a new gasket.

Tightening torque: 10 Nm (7 lbf ft)

17. Fit the ground cable and the pressure/temperature sensor connector on the throttle body.

18. Connect the turbocharger delivery pipe with hose to the throttle body.

19. Fit the Camshaft.


PRE-RELEASE