vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Solenoid Valve, Exhaust Gas Recirculation Valve, Remove and Install > < J470300 Gasket - Exhaust Manifold, Replace (Y 17 DTL, without AC, LHD)

Corsa C

Repair engine using an engine short block (Y 17 DT)

1.   Remove engine
Note:   See operation "J 450100 Removing and installing engine".
2.   Detach manual transmission from engine
Note:   See operation "J 450100 007 Detaching and attaching manual transmission from/to engine".
3.   Drain engine oil
•   Place collecting basin underneath.
•   Unscrew oil filter housing cover (1)
•   Remove oil filter element
•   Unscrew oil drain bolt
Object Number: 2411058 Size: DEFAULT


4.   Remove air intake pipe
•   Remove 2 bolts
•   Release clamp
•   Detach engine vent hose (1)
– From cylinder head cover
•   Unclip wiring harness (arrow)
Object Number: 2411065 Size: DEFAULT


5.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
– With KM-913-A
Note:   Mark direction of rotation
Object Number: 2411073 Size: DEFAULT


6.   Remove starter alternator wiring harness
•   Disconnect alternator
– Unscrew nut (2)
– Disconnect wiring harness plug (1)
•   Expose wiring harness
– 6 clips
– Remove bolt
•   Remove bracket with wiring harness
– Remove 2 nuts
•   Detach starter
– Unscrew bolt and nut
Object Number: 2411191 Size: DEFAULT


7.   Remove alternator
•   Remove 2 bolts (1)
•   Expose vacuum line
– Solenoid, vacuum pump
•   Remove oil feed line
– Unscrew banjo bolt
– Remove sealing ring
•   Detach oil return line
Object Number: 2411120 Size: DEFAULT


8.   Remove oil dipstick guide tube bracket
•   Unscrew 2 nuts, bolt
9.   Remove lower coolant hose
•   Release clamp
•   Place collecting basin underneath.
10.   Remove oil dipstick guide tube
•   Remove 2 bolts
11.   Remove exhaust manifold heat shield
•   Remove 4 bolts
Object Number: 2411066 Size: DEFAULT


12.   Remove turbocharger heat shield
•   Remove 3 bolts
13.   Detach vacuum hose from waste gate unit
14.   Remove turbocharger oil return hose (1)
•   Release clamp
– At engine block
Object Number: 2411144 Size: DEFAULT


15.   Remove turbocharger oil feed line
•   Unscrew banjo bolt (1)
•   Unscrew nut
Note:   Counterhold at threaded connection
•   Remove seal rings
Object Number: 2411068 Size: DEFAULT


16.   Remove exhaust recirculation pipe
•   Remove 2 bolts (1)
•   Remove gasket.
Object Number: 2411067 Size: DEFAULT


17.   Loosen turbocharger bracket
•   Remove bolt
18.   Remove exhaust manifold
•   Unscrew 7 bolts, 2 nuts (1)
•   Remove gasket.
Object Number: 2411069 Size: DEFAULT


19.   Remove alternator bracket
•   Remove 4 bolts (arrows)
Object Number: 2404429 Size: DEFAULT


20.   Remove coolant pipe (1)
•   Remove thermostat housing coolant hoses (2, 3)
•   Remove bolt
•   Pull coolant tube out of coolant flange
Object Number: 2416051 Size: DEFAULT


21.   Remove coolant flange
•   Remove 2 bolts
22.   Remove coolant drain screw
•   At engine block
23.   Remove oil circuit connecting pieces
•   2 off
24.   Remove engine control unit
•   Unscrew 2 bolts (2), 2 nuts (3)
•   Remove wiring harness plug bracket
– Remove 2 bolts (1)
Object Number: 2411079 Size: DEFAULT


25.   Remove engine control unit bracket
•   Unscrew 2 bolts (2), nut (1)
•   Unclip wiring harness (arrows)
Object Number: 2411080 Size: DEFAULT


26.   Remove injection pump insulators
•   Rear insulator
– Remove bolt
•   Remove lower insulator
27.   Remove engine management wiring harness
•   Disconnect wiring harness plug
– Coolant temperature sensor, oil pressure switch, injection pump, exhaust gas recirculation solenoid valve, sheathed glow plugs, charge pressure sensor
•   Undo 6 clips
28.   Remove upper charge air pipe (1)
•   Remove 2 bolts (arrows)
•   Remove studs (2)
Object Number: 2411081 Size: DEFAULT


29.   Remove exhaust recirculation valve (1)
•   Unscrew studs (3)
•   Remove 2 bolts (arrows)
•   Detach vacuum hose (2)
•   Remove gasket.
Object Number: 2411082 Size: DEFAULT


30.   Remove oil filter housing
•   Detach oil return line
– From cylinder block
•   Detach coolant hoses
– From cylinder block
– From oil filter housing
•   Remove bolt (1)
Object Number: 2411126 Size: DEFAULT


31.   Remove thermostat housing
•   Remove 2 bolts (arrows)
Object Number: 2411118 Size: DEFAULT


32.   Remove turbocharger vacuum hose
•   Remove bracket
– Remove bolt
– From cylinder head
33.   Remove oil pressure switch
34.   Remove starter
•   Remove lower bolt
35.   Remove right rear engine transport shackle
•   Remove bolt
36.   Remove injection pump insulator
37.   Remove injection pipe spacers (1)
Note:   Mark spacer positions
•   Remove 3 bolts
Object Number: 2411139 Size: DEFAULT


38.   Remove injection lines
•   With KM-6098
•   4 off
– Unscrew 8 union nuts
Object Number: 2411139 Size: DEFAULT


39.   Remove oil leak line hose
•   Release 2 clamps
40.   Remove intake manifold
•   Unscrew 7 bolts (1), 2 nuts (2)
•   Remove gaskets
Object Number: 2416084 Size: DEFAULT


41.   Detach right engine bracket (1)
•   Remove 3 bolts
Object Number: 2411072 Size: DEFAULT


42.   Remove coolant pump ribbed V-belt pulley
•   Remove 3 bolts
43.   Remove coolant pump (1)
•   Place collecting basin underneath.
•   Remove 5 bolts
•   Remove coolant pump plastic insert
Object Number: 2411116 Size: DEFAULT


44.   Remove upper toothed belt cover
•   Remove 8 bolts
Note:   Note dissimilar bolt lengths
•   Remove adapter for right engine bracket
Object Number: 2404431 Size: DEFAULT


45.   Remove torsional vibration damper (1)
•   Remove 4 bolts
Object Number: 2411100 Size: DEFAULT


46.   Detach lower part of toothed belt cover
•   Remove 3 bolts
Object Number: 2411099 Size: DEFAULT


47.   For toothed belt tension roller with leaf spring:
•   Remove toothed belt tensioner
– Remove bolt (2)
– Remove tension spring (1)
Object Number: 2411075 Size: DEFAULT


48.   For toothed belt tension roller with spiral spring:
•   Remove toothed belt tension roller (1)
– Remove bolt (2)
Object Number: 2406524 Size: DEFAULT


49.   Detach camshaft pulley
•   Unscrew TDC-fixing bolt (2)
•   Counterhold camshaft pulley with KM-6156 and KM-956-1
•   Remove bolt (1)
Object Number: 2411076 Size: DEFAULT


50.   Remove drive gear injection pumps
•   Unscrew nut
•   Unscrew TDC-fixing bolt
•   Attach KM-6099
Important:   Note woodruff keys
•   Removing injection pump drive gear
Object Number: 2411077 Size: DEFAULT


51.   Remove toothed belt deflection pulley (1)
•   Remove bolt (2)
Object Number: 2411101 Size: DEFAULT


52.   Remove toothed belt tension roller spring retainer
•   Remove 2 bolts
53.   Remove rear toothed belt cover
•   Remove 4 bolts
54.   Remove oil pump drive gear (1)
•   Unscrew nut
Note:   Counterhold with socket wrench (2).
Object Number: 2411145 Size: DEFAULT


55.   Remove crankshaft toothed belt drive gear (1)
•   Attach KM-662-C
•   Remove bolt
•   Remove KM-662-C
•   Attach KM-161-B (2)
– Remove plate
Object Number: 2405633 Size: DEFAULT


56.   Remove clutch
Note:   See operation "Removing and installing pressure plate and clutch disk (without SAC)" in group "K".
57.   Detach flywheel
•   Block using KM-652
•   Remove 8 bolts
Object Number: 2411158 Size: DEFAULT


58.   Remove injection pump holder (arrow)
•   Remove 4 bolts
Object Number: 2411153 Size: DEFAULT


59.   Remove injection pump
•   Remove 2 nuts (arrows)
•   Remove front injection pump insulation
Object Number: 2411154 Size: DEFAULT


60.   Remove crankshaft sensor(1)
•   Remove bolt (2)
Object Number: 2411113 Size: DEFAULT


61.   Remove oil pressure control valve (1)
•   Remove bolt
Object Number: 2411140 Size: DEFAULT


62.   Remove safety valve
•   Remove bolt
63.   Remove 2 engine transport shackles
•   Remove 2 bolts
64.   Remove 4 outer injection nozzle seals
•   Remove 8 bolts
Object Number: 2411085 Size: DEFAULT


65.   Remove camshaft housing cover
•   Unscrew 7 bolts (1), 3 studs (2)
Object Number: 2411156 Size: DEFAULT


66.   Remove inner oil leak line
•   Unscrew 5 banjo bolts (1)
Note:   Note sealing rings.
Object Number: 2411086 Size: DEFAULT


Important:   Ensure that upon removal of injector nozzles heat protection sleeves remain in their position on the cylinder head. Otherwise, heat protection sleeves must be removed completely and installed again using new sealing rings. This is the only way to ensure that no coolant can reach the combustion chamber, which would inevitably cause engine damage. Replace heat protection sleeves – see operation "Replace heat protection sleeves" in document "Check and measure cylinder head".
67.   Remove injector nozzles
68.   Remove injector nozzles
•   Remove injection nozzle bracket
– Remove 2 nuts (1)
•   Remove injector nozzles
Object Number: 2411150 Size: DEFAULT


69.   Remove camshaft housing cover
Important:   Follow order.
•   Loosen bolts, stud bolts (180°)
•   Unscrew 2 stud bolts, 15 bolts
•   Remove gasket.
Object Number: 2416020 Size: DEFAULT


70.   Remove cup tappets
•   With KM-845
•   Important! Note allocation and installation position
71.   Remove cylinder head bolts
•   Remove 10 bolts
Note:   Undo bolts in depicted order (180° to 360°).
Object Number: 2416025 Size: DEFAULT


Important:   Place cylinder head on wooden blocks. Note sheathed glow plugs.
72.   Remove cylinder head
Note:   2nd mechanic.
•   Remove cylinder head gasket
73.   Turn engine
•   180°
74.   Screw in oil drain screw
•   Replace seal ring
•   Tighten oil drain screw ( 78.4 Nm )
75.   Detach oil pan lower part
•   Remove 15 bolts
•   Remove using KM-J-37228
Object Number: 2411060 Size: DEFAULT


76.   Detach oil pan upper part
•   Remove 14 bolts
Note:   Note dissimilar bolt lengths
•   Remove 2 nuts
Note:   Use wide spatula.
77.   Detach oil intake pipe
•   Remove bolt (1)
•   Remove gasket.
78.   Remove oil baffle plate
•   Remove 5 bolts (arrows)
Object Number: 2411062 Size: DEFAULT


79.   Remove oil pump cover (1)
•   Remove 9 bolts
Note:   Note dissimilar bolt lengths
•   Remove inner and outer rotors (2)
Object Number: 2393053 Size: DEFAULT


80.   Clean components
•   Oil pan lower section, oil pan upper section, cylinder head, exhaust manifold, exhaust recirculation valve, coolant connections, oil pump cover
81.   Inspect components
82.   Remove cylinder block
•   Attach transport shackles
•   Attach KM-2358
•   Unscrew cylinder block
– From KM-412
– With workshop crane
•   Put down cylinder block
•   Remove KM-2358
•   Remove transport shackles
83.   Attach cylinder block
•   Attach transport shackles
•   Attach KM-2358
•   Lift cylinder block
•   Attach cylinder block
– An KM-412
•   Remove KM-2358
•   Remove transport shackles
84.   Drive in engine number
85.   Drive guide bushings into cylinder block
•   4 off
•   With KM-427
86.   Remove oil pump cover sealing rings
•   Front crankshaft sealing ring (1), oil pump sealing ring (2)
Important:   Do not damage sealing surfaces.
– Prise out sealing rings
Object Number: 2411148 Size: DEFAULT


87.   Attach oil pump cover (2)
•   Insert inner and outer rotor
– Coat with engine oil
•   Replace gasket (1)
•   Apply adhesive sealing compound (black) (shaded area)
•   Attach oil pump cover
Note:   Note guide bushings and differing bolt lengths.
– Tighten bolts ( 9.8 Nm )
Object Number: 2393052 Size: DEFAULT


88.   Install oil pump seal ring
•   Replace seal ring
•   Coat sealing lip with silicon grease (white)
•   Drive in until flush using KM-657
89.   Install front crankshaft sealing ring (1)
•   Replace seal ring
•   Coat sealing lip with silicon grease (white)
•   Drive in until flush using KM-656 (2)
Object Number: 2411149 Size: DEFAULT


90.   Install oil baffle plate
•   Tighten bolts ( 18.6 Nm )
91.   Attach oil intake pipe
•   Replace seal ring
•   Tighten bolt ( 18.6 Nm )
92.   Clean thread.
•   Oil pan upper section
– 14 off
•   Oil pan lower section
– 15 off
93.   Attach oil pan upper part
Important:   The application of silicone sealing compound (grey) and installation of lower part of oil pan including torque test must be performed within 10 minutes!
•   Apply silicon sealing compound (grey)
•   Tighten bolts, nuts ( 9.8 Nm )
94.   Attach oil pan lower section
•   Apply silicon sealing compound (grey)
•   Tighten bolts ( 9.8 Nm )
95.   Turn engine
•   90°
96.   Attach flywheel
•   Renew bolts
•   Block using KM-652
•   Tighten bolts ( 29,4 Nm + 60° + 15° )
97.   Install clutch
Note:   See operation "Removing and installing pressure plate and clutch disk (without SAC)" in group "K".
98.   Turn engine
•   90°
99.   Attach crankshaft toothed belt drive gear
•   Install sheet metal panel
•   Insert toothed belt drive gear in place
– Note woodruff key
•   Counterhold using KM-662-C
•   Tighten bolt ( 196 Nm )
100.   Check for plane surface
•   Cylinder head, cylinder block
•   With straightedge, feeler gauge
Object Number: 2416043 Size: DEFAULT


101.   Measure piston projection
•   Insert MKM-571-B (1) into KM-301 (2)
– Note pretension
•   Set dial to zero
– Place probe on cylinder block
•   Measure piston projection on all four pistons
– Carry out measurement on two different locations (3 and 4) or (5 and 6)
– Determine high point by turning crankshaft
•   Turn crankshaft
– approx. 60° before TDC of cylinder-1
Object Number: 2396362 Size: DEFAULT


102.   Replace cylinder head gasket

Piston projection

Thickness of cylinder head gasket

Code

0.630 – 0.696 mm

1.45 mm

no hole

0.697 – 0.763 mm

1.50 mm

one hole

0.764 – 0.830 mm

1.55 mm

two holes
Important:   The largest determined piston projection determines the selection of the cylinder head gasket with appropriate identification (arrows).
•   Lay cylinder head gasket in place
– Note guide bushings
Object Number: 2416028 Size: DEFAULT


103.   Attach cylinder head
Note:   2nd mechanic.
104.   Fasten cylinder head
•   Replace cylinder head bolts
– Screw in bolts by several threads
Important:   Note tightening order.
•   Tighten cylinder head bolts ( 39.2 Nm + 60° + 13°+ 60° + 13° )
Object Number: 2416029 Size: DEFAULT


105.   Insert cup tappets
Important:   Note order and allocation.
•   Coat with engine oil
106.   Install camshaft housing
•   Replace gasket
•   Tighten bolts M8 ( 21.6 Nm )
Important:   Follow order.
•   Tighten bolts M10 ( 43.1 Nm )
Object Number: 2416021 Size: DEFAULT


107.   Install safety valve
•   Replace seal ring
•   Tighten bolt ( 39.2 Nm )
108.   Install oil pressure control valve
•   Replace seal ring
•   Tighten oil pressure regulating valve ( 29.4 Nm )
109.   Install crankshaft sensor
•   Replace seal ring
•   Tighten bolt ( 9.8 Nm )
110.   Install injection pump
•   Insert front injection pump insulation
Note:   Note central position of stud in injection pump flange.
•   Tighten nuts
111.   Attach rear toothed belt cover
•   Tighten bolts ( 9.8 Nm )
112.   Attach toothed belt clamping roller spring retainer
•   Tighten bolts ( 9.8 Nm )
113.   Install oil pump drive gear
Note:   Pay attention to installation position
•   Tighten nut ( 44.1 Nm )
114.   Install toothed belt guide roller
•   Tighten bolt ( 80.4 Nm )
115.   Install injection pump drive gear
Important:   Observe tightening sequence
1. Tighten nut 60 Nm
2. Loosen nut
3. Waiting time: 60 sec
4. Tighten nut 60 Nm


•  
116.   Attach camshaft pulley
•   Block using KM-6156 and KM-956-1
•   Tighten bolt ( 63.7 Nm )
•   Install TDC-fixing bolt
117.   Install toothed belt tension roller
•   Screw in toothed belt tension roller bolt
•   For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner
118.   Set no.1 cylinder to TDC
•   Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)
Object Number: 2411092 Size: DEFAULT


119.   Install toothed belt
•   Position toothed belt
Note:   Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear
•   For toothed belt tension roller with leaf spring:
– Attach leaf spring
•   Unscrew TDC-fixing bolt
•   Rotate crankshaft 60° against direction of engine rotation
•   Tighten bolt of toothed belt tension roller
– For toothed belt tension roller with spiral spring 49 Nm
– For toothed belt tension roller with leaf spring 38.2 Nm
•   For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner
120.   Timing, Check
•   Turn crankshaft approx. 780° in direction of engine rotation
– At toothed belt drive gear bolt
•   The mark on toothed belt drive gear must align with lug on oil pump cover (arrows)
•   Install TDC-fixing bolt
– Camshaft gear M6 (1)
– Injection pump drive gear M8 (2)
Note:   If the TDC fixing bolts cannot be screwed in, basic adjustment must be repeated
•   Unscrew TDC-fixing bolts
Object Number: 2404425 Size: DEFAULT


121.   Remove bolt (M 10)
122.   Attach KM-798
•   Turn crankshaft in direction of engine rotation to 45° before no.1 cylinder TDC
– At toothed belt drive gear bolt
•   Remove central bleeder screw
•   Install KM-798 under pre-tension
•   Determine BDC position of injection pump plunger by turning crankshaft back and forth
Note:   Dial gauge needle must not move
•   Set dial gauge to "0".
Object Number: 2411155 Size: DEFAULT


123.   Adjust injection pump
•   Turn crankshaft to no.1 cylinder TDC
Note:   Mark on toothed belt drive gear must align with casting lug at oil pump cover.
•   Loosen diesel injection pump
•   Turn diesel injection pump until 0.33 mm adjustment value is accomplished
– Value too high – turn injection pump towards engine
– Value too low – turn injection pump away from engine
•   Tighten diesel injection pump ( 19.6 Nm )
124.   Check start of feed
•   Remove KM-798
•   Turn crankshaft approx. 675°
•   Install KM-798 under pre-tension
•   Determine BDC position of injection pump plunger by turning crankshaft back and forth
Note:   Dial gauge needle must not move
•   Set dial gauge to "0".
•   Turn crankshaft to 1st Cylinder TDC
Note:   Mark on toothed belt drive gear must align with casting lug at oil pump cover.
Important:   Repeat adjustment if test value is not achieved!
•   Read test value
– Test value: 0.28 – 0.38 mm
125.   Remove KM-798
•   Remove dial gauge
•   Tighten central bleeder screw ( 23.5 Nm )
– Replace seal ring
126.   Attach injection pump bracket
•   Tighten bolts to cylinder block ( 53.9 Nm )
•   Tighten bolt to injection pump ( 18.6 Nm )
127.   Turn crankshaft
•   Turn crankshaft until cam pairs (1) and (2) point upwards
Object Number: 2415968 Size: DEFAULT


128.   Check valve clearance
•   Using feeler gauge
– Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm)
129.   Adjust valve clearance
•   Turn cup tappet until tappet groove points outwards
Important:   Ensure that valves do not interfere with piston head
•   Press down cup tappets using KM-6090
Note:   Note different tool versions for intake and exhaust valves
– Mark – IN = Intake side
– Mark – EX = Exhaust side
•   Remove adjustment shim
Example for determination of shim thickness

1.

Thickness of installed shim

 

3.15 mm

2.

Measurement between cam and cup tappets

+

0.45 mm

 

 

=

3.60 mm

3.

Nominal valve play

-

0.40 mm

4.

Thickness of new shim

=

3.20 mm

130.   Insert adjustment shim
•   Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards
Object Number: 2415969 Size: DEFAULT


131.   Check and adjust valve clearance
•   Turn crankshaft
•   In direction of engine rotation by 180°
– Check and adjust valve pair (6) and (2)
•   In direction of engine rotation by 180°
– Check and adjust valve pair (5) and (3)
•   In direction of engine rotation by 180°
Note:   Clearance of all adjusted valves must be re-checked
– Check and adjust valve pair (4) and (1)
Object Number: 2415969 Size: DEFAULT


132.   Install injector nozzles
•   Replace seal rings (1)
•   Replace copper seal rings (2)
•   Insert injection nozzles in cylinder head.
•   Install injection nozzle bracket
•   Attach injection nozzle bracket ( 22.1 Nm )
Object Number: 2416067 Size: DEFAULT


133.   Install inner oil leak line
•   Renew seal rings
•   Tighten banjo bolt ( 14.7 Nm )
134.   Install camshaft housing cover
•   Replace gasket
Important:   Oil return bore (2) must not be covered with adhesive sealing compound or by the camshaft housing cover gasket
•   Apply adhesive sealant compound (white)
– Areas (1, 3)
•   Tighten bolts, studs ( 9.8 Nm )
Object Number: 2416086 Size: DEFAULT


135.   Install outer injection nozzle seal
•   Replace seals
Note:   Pay attention to installation position
•   Tighten bolts
136.   Attach engine transport shackles
•   2 off
•   Tighten bolts ( 24.5 Nm )
137.   Install lower toothed belt cover
•   Tighten bolts ( 9.8 Nm )
138.   Install torsional vibration damper
•   Tighten bolts ( 19.6 Nm )
139.   Install right engine bracket adapter
•   Insert lower bolt
– Into right engine bracket and right engine bracket adapter
•   Insert right engine bracket, right engine bracket adapter, upper part of toothed belt cover
•   Install 2 upper bolts
•   Tighten 3 bolts( 40 Nm )
140.   Install upper toothed belt cover
•   Tighten bolts ( 9.8 Nm )
Note:   Note dissimilar bolt lengths
141.   Install coolant pump
•   Replace gasket
•   Tighten bolts ( 23.5 Nm )
142.   Install coolant pump ribbed V-belt pulley
•   Tighten bolts ( 9.8 Nm )
143.   Install intake manifold
•   Replace gasket
•   Tighten bolts, nuts ( 24.5 Nm )
144.   Install oil leak line hose
145.   Install injection lines
•   Important! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump.
•   Tighten union nut ( 22.5 Nm )
146.   Install injection line spacers
Note:   Pay attention to spacer positions
•   3 off
147.   Install starter
•   Tighten lower bolt ( 38.2 Nm )
148.   Attach oil filter housing
•   Renew seal rings
– 2 off
•   Tighten bolt ( 23.5.5 Nm )
•   Attach oil return line
•   Attach coolant hose
149.   Install oil filter element
•   Tighten oil filter housing cover ( 23.5 Nm )
150.   Install right rear engine transport shackle
•   Tighten bolt ( 24.5 Nm )
151.   Install exhaust gap return valve
•   Replace gaskets
•   Tighten studs, bolts
– At intake manifold ( 24.5 Nm )
•   Connect vacuum hose.
152.   Attach upper charge air pipe
•   Clean sealing surface
•   Replace gasket
•   Tighten studs, bolts
•   Upper charge air pipe bracket to camshaft housing
– Tighten bolt ( 24.5 Nm )
153.   Install oil pressure switch
Note:   Clean thread in cylinder head.
•   Apply silicon sealing compound (grey) to thread
•   Tighten oil pressure switch ( 20.6 Nm )
154.   Install turbocharger vacuum hose
•   Attach bracket
– Bolt in bolt
155.   Attach thermostat housing
•   Replace gasket
•   Tighten bolts ( 23.5 Nm )
•   Attach coolant hose
– At oil cooler
156.   Install motor management wiring harness
•   Connect wiring harness plug.
– Coolant temperature sensor, oil pressure switch, injection pump, exhaust gas recirculation solenoid valve, sheathed glow plugs, charge pressure sensor
•   Attach 6 clips
157.   Install injection pump insulation
•   3 off
•   Tighten bolt
158.   Install engine control unit bracket
•   Tighten bolts, nut ( 9.8 Nm )
•   Attach engine management wiring harness bracket
•   Clip in engine management wiring harness
159.   Install engine control unit
•   Tighten bolts, nuts ( 5.9 Nm )
•   Attach engine management wiring harness plug
Note:   Note installation direction.
•   Install wiring harness plug bracket
– Tighten 2 bolts
160.   Attach coolant drain screw
161.   Attach oil circuit connection pieces
•   2 off
162.   Attach coolant flange
•   Apply adhesive sealant compound (light grey)
•   Tighten bolts
163.   Attach coolant pipe
•   Replace gasket
•   Tighten bolt ( 95.1 Nm )
•   Attach coolant hoses
164.   Attach alternator bracket
•   Tighten bolts M10 ( 48 Nm )
•   Tighten bolts M14 ( 67.6 Nm )
165.   Attach exhaust manifold
•   Replace gasket
•   Tighten bolts, nuts ( 23.5 Nm )
166.   Attach turbocharger bracket
•   Tighten bolt
167.   Attach exhaust gas recirculation pipe
•   Replace gasket
•   Tighten bolts( 28.4 Nm )
168.   Attach turbocharger oil feed line
•   Renew seal rings
•   Tighten banjo bolt ( 9.8 Nm )
•   Tighten nuts ( 9.8 Nm)
Note:   Counterhold at threaded connection
169.   Install turbocharger oil return hose
•   Fasten clamp
170.   Attach waste gate unit vacuum hose
171.   Install turbocharger heat shield
•   Tighten bolts ( 11.7 Nm )
172.   Install exhaust manifold heat shield
•   Tighten bolts ( 11.7 Nm )
173.   Install oil dipstick guide tube
•   Replace gasket
•   Tighten bolts ( 9.8 Nm )
174.   Attach lower coolant hose
•   Fasten clamp
175.   Install oil dipstick guide tube bracket
•   Tighten nuts ( 9.8 Nm )
•   Tighten bolt
176.   Attach alternator
•   Tighten bolts
– M10 ( 46.1 Nm )
– M8 ( 18.6 Nm )
•   Attach oil return line
•   Install oil feed line
– Renew seal rings
– Tighten banjo bolt ( 21.6 Nm )
•   Route vacuum lines
177.   Install starter alternator wiring harness
•   Starter
– Tighten bolt
– Tighten nuts ( 9.8 Nm )
•   Attach bracket with wiring harness
– Tighten nuts
•   Route wiring harness and clip in
– Tighten bolt
•   Connect alternator
– Tighten nuts
– Connect wiring harness plug.
178.   Install ribbed V-belt
Note:   Observe running direction
•   Release ribbed V-belt tensioner
179.   Install air intake pipe
•   Tighten bolts
•   Fasten clamp ( 5 Nm )
•   Attach engine vent hose
– Fasten clamp
•   Attach wiring harness
180.   Pour in engine oil
•   Observe specified engine oil quantity
181.   Attach manual transmission to engine
Note:   See operation "J 450100 007 Detaching and attaching manual transmission from/to engine".
182.   Install engine
Note:   See operation "J 450100 Removing and installing engine".
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Solenoid Valve, Exhaust Gas Recirculation Valve, Remove and Install > < J470300 Gasket - Exhaust Manifold, Replace (Y 17 DTL, without AC, LHD)