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Attaching Parts - Cylinder Head, Remove and Install (Z16XEP) > < Cylinder Head Cover, Remove and Install

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Cylinder Head, Remove and Install (Z16XEP)

  Remove

1.   Open bonnet
2.   Disconnect earth connection from battery
•   Slacken nut
3.   Remove air cleaner housing - Z16XEP LUREF_1.gif
4.   Remove DIS-ignition module
•   Remove cover of DIS-ignition module in the direction of the arrow
Note:   Note arrow on cover
•   Unscrew 2x bolts
•   Detach from spark plugs using KM-6009 (1)
Object Number: 2412812 Size: DEFAULT


5.   Detach ribbed V-belt (1)
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner (2) in the direction of the arrow and fix with KM-6130 (3)
– Remove ribbed-V-belt
Object Number: 2412799 Size: DEFAULT


6.   Raise vehicle by its full height
7.   Place collecting basin underneath.
8.   Drain coolant
•   Open drain bolt on radiator
•   Collect coolant
•   Close drain bolt
9.   Detach the lower engine cover and lower engine splash guard
10.   Expose wiring harness for catalytic converter control oxygen sensor (1)
•   Unfasten cable tie (2)
•   Disconnect wiring harness connector (3)
Object Number: 2412787 Size: DEFAULT


11.   Detach front exhaust pipe (2) from catalytic converter
•   Unscrew 3x nuts (1)
Object Number: 3446323 Size: DEFAULT


12.   Remove gasket and clean sealing surface
13.   Detach intake manifold support (3) from cylinder block
•   Unscrew bolt (2)
•   Remove vacuum hose (1)
14.   Disconnect wiring harness plug (5) from tank vent valve (4)
Object Number: 2412791 Size: DEFAULT


15.   Disconnect tank vent valve hose (1)
•   Unlatch tank vent valve hose in the direction of the arrow
Object Number: 2412771 Size: DEFAULT


16.   Release fuel pressure via test connection (1) using KM-J-34730-91 (2)
•   Collect exiting fuel in a suitable container - observe safety regulations and national legislation
Object Number: 2412772 Size: DEFAULT


17.   Detach fuel line (2) from fuel rail
•   Disconnect with KM-796-A (1)
Object Number: 2412773 Size: DEFAULT


18.   Detach coolant hose (2) from throttle valve body (1)
•   Release clamp
– Unclip coolant hose
Object Number: 2412774 Size: DEFAULT


19.   Disconnect coolant hoses from heater core
•   Detach 2x coolant hoses (1)
– Detach in direction of arrow
Object Number: 2412779 Size: DEFAULT


20.   Detach engine wiring harness from engine control unit
•   Remove earth cable (2)
– Unscrew bolt
•   Disconnect 2x wiring harness plug, engine control unit (1)
Object Number: 3446343 Size: DEFAULT


21.   Disconnect wiring harness plug (1) from intake pipe pressure sensor (2)
Object Number: 2412794 Size: DEFAULT


22.   Disconnect camshaft sensor wiring harness plug
•   Expose wiring harness
23.   Disconnect wiring harness plug, PDA system vacuum unit (1)
Object Number: 2412852 Size: DEFAULT


24.   Disconnect thermostat wiring harness plug (1)
25.   Disconnect wiring harness plug for coolant temperature sensor (3)
26.   Disconnect wiring harness plug of EGR valve (4)
Object Number: 2412964 Size: DEFAULT


27.   Disconnect wiring harness plug (2) of crankshaft pulse pick-up (1)
Object Number: 2412990 Size: DEFAULT


28.   Remove brake force amplifier vacuum line (1)
29.   Disconnect throttle valve body wiring harness plug (2)
Object Number: 2412795 Size: DEFAULT


30.   Expose engine wiring harness
•   Open 2x clip (1) and (2)
•   Unclip wiring trough (3)
– Set engine wiring harness aside
Object Number: 2412796 Size: DEFAULT


31.   Detach engine vent pipe (1) from cylinder head cover (3)
•   Unlatch fuse clamp (2)
Object Number: 2412797 Size: DEFAULT


32.   Detach front toothed belt cover (top) (1)
•   Unscrew 2x bolts (2)
•   Release upper catch (3)
•   Pull front toothed belt cover (top) upwards by cast projection (arrow), applying slight tension
Object Number: 2412882 Size: DEFAULT


33.   Raise vehicle by its full height
34.   Detach catalytic converter support
•   Unscrew 2x bolts (1)
Object Number: 2412785 Size: DEFAULT


35.   Possibility 1: Lock flywheel
•   Remove closure plugs
•   Insert KM-911 (1)
Object Number: 2412823 Size: DEFAULT


36.   Possibility 2: Lock crankshaft
•   Attach KM-6625
– Detach screwed connection (1)
– Insert KM-6625 (2)
– Tighten screwed connection (3)
Object Number: 9007701 Size: DEFAULT


37.   Detach torsional vibration damper (3)
•   Unscrew bolt (4)
38.   Detach ribbed V-belt tensioner (1)
•   Unscrew bolt (2)
– Ribbed V-belt tensioner remains locked with KM-6130
Object Number: 3446322 Size: DEFAULT


39.   Detach front toothed belt cover (bottom) (2)
•   Unscrew 4x bolts (1)
Object Number: 2412824 Size: DEFAULT


40.   Set engine to TDC
•   Remove KM-911 or KM-6625
•   Screw in bolt, torsional vibration damper
•   Move crankshaft in direction of engine rotation to "cylinder 1 TDC of combustion stroke" (III)
41.   Lower vehicle by its full height
42.   Lock camshaft sprockets in position with KM-6340
•   Position camshaft sprockets in such a way that the markings (arrows) are opposite each other
•   Attach KM-6340-Left to intake camshaft sprocket (I)
•   Insert KM-6340 (II)
43.   Remove toothed belt
•   Mark direction of rotation
•   Apply tension to toothed belt tension roller clockwise, using an Allen key and fix using KM-6333 (IV)
– Remove toothed belt
Object Number: 2412820 Size: DEFAULT


44.   Detach lower coolant hose (1) from thermostat housing (2)
•   Open clip (3)
•   Release clamp
Object Number: 3446325 Size: DEFAULT


45.   In design with oil pressure switch on cylinder head: Remove cover (2)
•   Disconnect wiring harness plug, cylinder head oil pressure switch (4)
– Unclip wiring harness, cylinder head oil pressure switch (3)
•   2 bolts (1)
Object Number: 3446324 Size: DEFAULT


46.   For design with cylinder head oil pressure switch: Remove cylinder head oil pressure switch (1)
47.   Remove mixture regulator oxygen sensor (3)
•   Unclip wiring harness plug for mixture regulator oxygen sensor
– Disconnect wiring harness connector.
48.   Remove engine transport shackle (4)
•   Unscrew bolt (5)
49.   Detach heat shield (2) from exhaust manifold
•   Unscrew 3 bolts
Object Number: 2412789 Size: DEFAULT


50.   Detach exhaust manifold (2) from cylinder head
•   Unscrew 11x nuts (1)
Object Number: 2412790 Size: DEFAULT


51.   Remove exhaust manifold gasket
52.   Clean sealing surfaces.
53.   Remove coolant pipe (1)
•   Unscrew 5x bolts (2), (3) and (4)
Object Number: 2412807 Size: DEFAULT


54.   Detach cylinder head cover (1)
•   Unclip wiring trough
•   Unlatch and remove engine vent pipe
•   Slacken 3x bolt (3) pull upwards and fix in this position with adhesive tape
•   Slacken 6x bolts (2)
Note:   Care should be taken that the area of the front camshaft bearing caps (arrows) is clean and free from remains of sealant
Object Number: 2412908 Size: DEFAULT


Important:   Remove cylinder head only when engine is cold (room temperature)
55.   Remove cylinder head
•   Unscrew 10x bolt
Note:   Unfasten bolts in the order shown
– Undo 10x bolts (90°)
– Undo 10x bolts (180°)
Object Number: 2412813 Size: DEFAULT


56.   Remove cylinder head
Note:   Second mechanic
•   Lay cylinder head on suitable base
•   Remove cylinder head gasket
57.   Clean sealing surfaces.
58.   Cylinder Head, Check for Plane Surface LUREF_1.gif

  Install

59.   Position cylinder head
•   Install cylinder head gasket
Note:   Second mechanic
Important:   Check installation position
•   Position cylinder head
60.   Install cylinder head
•   Tighten 10x bolt 25 Nm + 90° + 90° + 90° + 45°
Note:   Note correct tightening sequence
– Use new cylinder head bolts
Object Number: 2398342 Size: DEFAULT


61.   Replace gasket, cylinder head cover
•   Insert new gasket (1) in cylinder head cover
Object Number: 2412955 Size: DEFAULT


62.   Remove spark plug, cylinder 1 with KM-6363
63.   Install KM-6354 (1) in spark plug thread, cylinder 1
Object Number: 2412922 Size: DEFAULT


Important:   When assembling the cylinder head, care must be taken that the cylinder head cover gasket does not become detached.
An incorrectly fitted cylinder head cover gasket can lead to serious damage to the engine
64.   Place cylinder head cover in position
•   Lift cylinder head cover via KM-6354
•   Position cylinder head cover at the rear (i)
•   Press cylinder head cover carefully downwards at the back (II)
•   Remove KM-6354 (1)
Object Number: 2412923 Size: DEFAULT


65.   Attach cylinder head cover
•   Remove adhesive tape from 3 bolts
•   Tighten 12x bolt 8 Nm
•   Attach engine vent pipe and latch
•   Clip in wiring trough
66.   Install DIS ignition module (1)
•   Replace gaskets (2)
•   Tighten 2x bolt 8 Nm
•   Attach DIS ignition module cover
Object Number: 2412945 Size: DEFAULT


67.   Install coolant pipe
•   Tighten 5x bolt 10 Nm
68.   Install exhaust manifold gasket
•   Observe correct fitting position
69.   Attach exhaust manifold to cylinder head.
Note:   Tighten nuts in a spiral, working from inside to outside
•   Tighten 11x nut 15 Nm
– Use new nuts
70.   Replace heat shield
71.   Attach heat shield to exhaust manifold
•   Tighten 3x bolt 8 Nm
72.   Fit engine transport shackle
•   Tighten bolt 25 Nm
73.   Install oxygen sensor mixture regulator
•   Coat mixture regulator oxygen sensor with special grease
•   Screw in mixture regulator oxygen sensor 40 Nm
•   Fix wiring harness plug
•   Lay mixture regulator oxygen sensor wiring harness
74.   For design with oil pressure switch in cylinder head: install cylinder head oil pressure sensor with new gasket 20 Nm
75.   In design with oil pressure switch in cylinder head: Remove cover
•   Tighten 2x bolts
•   Connect wiring harness plug of oil pressure sensor
– Lay wiring harness, oil pressure sensor
76.   Insert toothed belt
Note:   Threading the toothed belt through the engine damping block support is only permissible in conjunction with the assembly tool supplied with new toothed belts as otherwise it is possible to damage the toothed belt at this stage by kinking it
•   Insert toothed belt (1) in enclosed assembly tool (2)
– If the toothed belt has been used, observe direction of rotation
•   Guide toothed belt through engine damping block support with assembly tool
•   Remove assembly tool
Object Number: 2412961 Size: DEFAULT


77.   Position toothed belt
Note:   If the toothed belt has been used, observe direction of rotation
•   Place toothed belt on exhaust camshaft sprocket
•   Place toothed belt on intake camshaft sprocket
•   Guide toothed belt past the tensioning and guide rollers and place on toothed belt drive gear
•   Apply tension to the toothed belt tension roller and remove KM-6333
78.   Remove KM-6340
79.   Raise vehicle by its full height
80.   Turn crankshaft through 720°
•   2 revolutions in direction of engine rotation
•   Place toothed belt drive gear on the marking, cylinder 1 TDC of combustion stroke
81.   Lower vehicle by its full height
82.   Lock camshaft sprockets in position with KM-6340
•   Insert KM-6340-Left
•   Insert KM-6340-Right
Note:   Markings on camshaft sprockets must align - otherwise dismantle toothed belt and place in position again
83.   Remove KM-6340
84.   Raise vehicle by its full height
85.   Attach front toothed belt cover (bottom)
•   Tighten 4x bolt 6 Nm
86.   Remove bolt on torsional vibration damper
•   Lock flywheel with KM-911 or KM-6625
87.   Fit torsional vibration damper
Important:   Use new bolt
•   Tighten bolt 95 Nm + 45° + 15°
88.   Possibility 1: Remove KM-911
•   Install closure plug
89.   Possibility 2: Detach KM-6625
•   Detach screwed connection
•   Tighten bolted connection
– Use new nuts
90.   Attach ribbed V-belt tensioner
•   Tighten bolt 50 Nm
91.   Insert ribbed V-belt
Note:   Observe direction of rotation
•   Apply tension to ribbed V-belt tensioner anti-clockwise and place ribbed V-belt in position
•   Remove KM-6130
92.   Attach the lower engine cover and right engine splash guard
93.   Attach catalytic converter support to catalytic converter
•   Tighten 2x bolt 20 Nm
94.   Attach intake manifold support to cylinder block
•   Tighten bolt 8 Nm
•   Attach vacuum hose
•   Connect tank vent valve wiring harness plug
95.   Attach front exhaust pipe to exhaust manifold
•   Use new gasket
•   Tighten 3x nut 20 Nm
96.   Lower vehicle by its full height
97.   Attach engine vent pipe to cylinder head cover
•   Connect and latch
98.   Attach engine wiring harness
•   Fix wiring harness plug
– Throttle valve body, crankshaft pulse pick-up, EGR valve, coolant temperature sensor, thermostat, PDA-system, camshaft sensor, intake pipe pressure sensor, engine control unit
•   Attach wiring trough, injectors
– Push on to injectors
•   Clip wiring harness into mountings
Important:   Ensure that it is latched correctly
99.   Attach front toothed belt cover (top)
•   Tighten 2x bolt 6 Nm
Important:   It is imperative to adhere to the following assembly order
100.   Attach cooling hoses to heater core
•   Fit 2x quick release fittings (1) onto heater core connection port (2) as far as they will go
Note:   Pay attention to coloured markings
•   Slide the 2x quick-release fitting catches (3) in the direction of the arrow all the way to the stop by simultaneously pressing the release buttons (4)
– The colour rings (5) must be visible
•   Check that quick release fittings are correctly seated and that the colour rings (5) are visible
Object Number: 10680549 Size: DEFAULT


101.   Attach lower coolant hose to thermostat housing
•   Fasten clamp
102.   Attach coolant hose, throttle valve body
•   Fasten clamp
103.   Attach fuel line to fuel rail
104.   Remove air cleaner housing - Z16XEP LUREF_1.gif
105.   Attach earth connection to battery
•   Tighten nut
106.   Top up coolant, correct if necessary
107.   Program volatile memories
108.   Close bonnet

Attaching Parts - Cylinder Head, Remove and Install (Z16XEP) > < Cylinder Head Cover, Remove and Install