J330100 All Pistons with Con-rod, Remove and
Install (Z 18 XE, with Air Conditioning, LHD)
Note: KM-6394 must be used as of model year 04 instead of
KM-6169-1 .
Note: The customer
should be informed of the choice between ECOService and
ECOService-Flex before the oil change.
Remove
2. |
Disconnect battery
Note: In vehicles from
model year 04 onwards with ESP - the steering angle sensor loses
its basic adjustment each time the battery is disconnected and must
be recalibrated.
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3. |
Remove engine cover.
• |
Unscrew oil filler pipe cap
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• |
Screw on oil filler pipe cap
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4. |
Remove air cleaner housing (1)
• |
Disconnect 2 wiring harness plugs
– |
Hot film mass air flow meter (4), tank vent valve (2)
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• |
Detach engine vent hose (3)
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5. |
Remove upper part of toothed belt cover
• |
Unscrew 3 bolts (arrows)
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• |
Unclip from rear toothed belt cover
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7. |
Remove right-hand air duct
• |
Unscrew 3 bolts (arrows)
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8. |
Remove ribbed V-belt cover
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10. |
Detach front right wheel
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12. |
Remove right front wheel.
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14. |
Remove ribbed V-belt
• |
Tension ribbed V-belt tensioner in direction of arrow with
KM-913-A (2)
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15. |
Remove ribbed V-belt tensioner
• |
Tension ribbed V-belt tensioner.
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• |
Release ribbed V-belt tensioner
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16. |
Detach crankshaft ribbed V-belt pulley
• |
Prise front closure plug out of oil pan
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17. |
Release lower part of toothed belt cover
• |
Unclip from rear toothed belt cover
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19. |
Loosen exhaust system
Note: Bends in the flex
pipe with an angle as little as 5 – 10 degrees from the
intended installation position may result in damage with subsequent
total failure of the flex pipe.
• |
When removing the centre muffler, a catalytic converter, an
exhaust manifold or an exhaust manifold with catalytic converter,
the exhaust system piece remaining in the vehicle must be prevented
from swinging uncontrollably.
Note: The exhaust
system piece with the flex pipe inside can be secured for this
purpose using suitable means, such as a wire on the vehicle
underbody.
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• |
Remove wiring harness plug for catalytic converter control
oxygen sensor
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• |
Suspend front exhaust pipe from left front axle body
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20. |
Release shift guide (3)
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Remove retaining clip (2)
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21. |
Release rear reaction member (4)
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22. |
Remove front reaction member
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24. |
Use MKM-883-1 (1)
Note: Second person
required
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25. |
Fasten MKM-883-1
Note: Observe
manufacturer's instructions
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26. |
Attach engine
• |
To right engine transport shackle (3)
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• |
To front left engine transport shackle (2)
Note: The front left
engine transport shackle is used only to stabilise the engine
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27. |
Detach right engine damping block
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28. |
Lift engine
• |
Carefully raise the engine approx. 40 mm on the timing side
with MKM-883-1
Note: Observe
manufacturer's instructions
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30. |
Remove oil pan
• |
Lever out rear sealing plug (1)
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• |
Oil pump
– |
Unscrew 3 bolts (arrows)
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32. |
Lower engine
Note: When lowering pay
attention to the shift guide and rear reaction member
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34. |
Fasten rear reaction member
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35. |
Install front reaction member
• |
Tighten bolted connection 60 Nm
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36. |
Attach KM-6169 (1)
• |
Attach KM-6169 to left of front axle
body (arrows, illus. I)
Note: Guide pin must be
seated in bore in front axle body
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• |
Attach both right holders on the front axle body (arrows,
Illus. II).
Note: Guide pin must be
seated in bore in front axle body (arrow, Fig. III)
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37. |
Install support to KM-6169
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Adjust bracket (2) for support
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38. |
Adjust supports
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Transmission side
– |
Turn spindles until mounts (3) are positioned at guide journals
free of play
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• |
Engine timing side
– |
Insert journal of the support in the bore of the cylinder block
without play (arrow)
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40. |
Drain coolant
• |
Place collecting basin underneath.
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• |
Open drain bolt (arrow)
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43. |
Remove MKM-883-1
Note: Second person
required
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44. |
Remove right engine damping block
• |
Loosen engine bracket adapter
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45. |
Remove preheater line for throttle valve module
• |
Disconnect wiring harness plug for coolant temperature
sensor
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46. |
Remove upper part of toothed belt cover
• |
Unclip from rear toothed belt cover
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47. |
Remove camshaft sensor (2)
• |
Disconnect wiring harness plug (1)
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48. |
Remove lower part of toothed belt cover
• |
Unclip from rear toothed belt cover
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49. |
Set 1st cylinder to TDC of combustion stroke
• |
Install crankshaft V-belt pulley bolt
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• |
Set crankshaft to mark.
– |
Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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• |
Fix camshaft sprockets in position.
– |
Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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50. |
Remove toothed belt
Note: Mark running
direction.
• |
Release toothed belt tension roller (IV)
– |
Turn adjusting eccentric in direction of arrow (clockwise)
until pointer (1) of the toothed belt tension roller is located
just before left stop.
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51. |
Remove ignition module
• |
Disconnect wiring harness plug (2)
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• |
Extract using KM-6009 (1)
Note: Do not tilt
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52. |
Remove cylinder head cover
• |
Detach engine vent hose
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• |
Unclip wiring harness of mixture regulation heated oxygen
sensor
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53. |
Remove camshaft sprockets
• |
Unscrew 2 bolts
– |
Counterhold camshafts at hexagonal section
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54. |
Remove exhaust side toothed belt guide roller
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55. |
Remove intake side toothed belt guide roller
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56. |
Remove right engine bracket (3)
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57. |
Remove toothed belt tension roller
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59. |
Remove toothed belt drive pulley
• |
Unscrew crankshaft ribbed V-belt pulley bolt
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60. |
Release rear toothed belt cover
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61. |
Release alternator
• |
Release alternator support
– |
Unscrew 2 upper bolts (1)
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62. |
Detach intake manifold support
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63. |
Remove wiring harness for engine management
• |
Disconnect 2 wiring harness plugs
– |
Oil pressure switch (1), crankshaft sensor (arrow)
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65. |
Remove rear of toothed belt cover
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66. |
Pull fuel evaporation hose from throttle valve module
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67. |
Remove alternator shackle
• |
Remove ground cable (1)
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• |
Unscrew 2x bolts (4, 5)
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Swing alternator backwards.
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Important: Observe safety
precautions and national regulations
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68. |
Release fuel pressure with KM-J-34730-91 on fuel distributor pipe
• |
Unscrew test connection protective cap
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69. |
Detach fuel line (1) from fuel distributor pipe
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70. |
Remove wiring harness for engine management
• |
Disconnect 7x wiring harness plugs
– |
Throttle valve module (1), engine control unit (3), knock
sensor (4), combination plug (5), EGR valve (6), mixture regulation
oxygen sensor (2)
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• |
Remove wiring trough
– |
Unscrew from engine transport shackle (arrow)
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• |
Set wiring harness to one side
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71. |
Remove fuel distributor pipe
• |
Unscrew 2x bolt (arrows)
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• |
Pull out fuel distributor pipe with injectors and engine
management wiring harness
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72. |
Detach preheater return hose for throttle valve module from
throttle valve module
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73. |
Detach heating return hose from intake manifold
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74. |
Remove right rear engine transport shackle
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75. |
Remove intake manifold
• |
Unscrew 7x nuts (arrows)
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• |
Remove brake servo vacuum line
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77. |
Detach centre coolant hose from coolant pump connection,
coolant flange
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78. |
Detach upper radiator hose from thermostat housing
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79. |
Remove intake pipe
• |
Pull intake pipe out of bracket
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80. |
Remove heated oxygen sensor for mixture regulation
• |
Screw out carefully using KM-6129
(1)
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81. |
Remove exhaust manifold heat shield
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82. |
Detach oil dipstick guide tube
• |
Swivel the oil dipstick guide tube to one side
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83. |
Remove exhaust manifold
• |
Unscrew 10x nut
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Remove engine transport shackle
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84. |
Remove cylinder head bolts
Note: Undo bolts in
order shown
• |
Unscrew 10 bolts
– |
Loosen 10x bolts (90 °)
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Loosen 10x bolts (180 °)
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85. |
Remove cylinder head
Note: Second person
required
• |
Place cylinder head on wooden blocks
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• |
Remove cylinder head gasket
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87. |
Remove con-rod bearing cap (1)
Note: Observe cylinder
sequence
• |
Mark con-rods with con-rod bearing caps
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• |
Unscrew 4 bolts
Note: The mating
surfaces of the cod-rods and con-rod bearing caps form an
individual fit and must not be damaged or interchanged. Do not lay
on mating surfaces.
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• |
Push piston with con-rod upwards
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91. |
Rotate crankshaft in direction of engine rotation
(180°)
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92. |
Remove con-rod bearing cap (1)
Note: Observe cylinder
sequence
• |
Mark con-rods with con-rod bearing caps
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• |
Unscrew 4 bolts
Note: The mating
surfaces of the cod-rods and con-rod bearing caps form an
individual fit and must not be damaged or interchanged. Do not lay
on mating surfaces.
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Push piston with con-rod upwards
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95. |
Remove con-rod bearing shells
Note: Note sequence
• |
Mark con-rod bearing shells
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Install
96. |
Inspect crank drive components
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97. |
Insert con-rod bearing shells into con-rods and con-rod bearing
caps
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98. |
Adjust piston ring gaps
• |
Turn piston rings
– |
Upper rings in position (1)
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– |
Middle rings in position (4)
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• |
Turn oil scraper ring
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Intermediate ring in position (5)
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Steel band rings in position (2) or (3)
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99. |
Install piston
Note: Arrow (1) on
bottom of piston points to engine timing side. Bead (2) on con-rod
should face transmission side
• |
Coat piston and cylinder bores with engine oil
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• |
Compress piston rings with piston ring tensioner
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101. |
Attach con-rod bearing cap
Note: Bead on con-rod
bearing cap should face transmission side
• |
Coat con-rod journal with engine oil
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• |
Tighten 4x bolts 25 Nm + 30°
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102. |
Rotate crankshaft in direction of engine rotation
(180°)
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104. |
Install piston
Note: Arrow (1) on
bottom of piston points to engine timing side. Bead (2) on con-rod
should face transmission side
• |
Coat piston and cylinder bores with engine oil
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• |
Compress piston rings with piston ring tensioner
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106. |
Attach con-rod bearing cap
Note: Bead on con-rod
bearing cap should face transmission side
• |
Coat con-rod journal with engine oil
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• |
Tighten 4x bolts 25 Nm + 30°
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108. |
Clean sealing surfaces
• |
Cylinder block, crankshaft bearing bridge, oil pan, cylinder
head, timing case, exhaust manifold, oil filter housing, thermostat
housing, cylinder head cover
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109. |
Check for plane surface
• |
Cylinder head, cylinder block
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• |
With straightedge, feeler gauge
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110. |
Attach cylinder head
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Attach cylinder head gasket
– |
OBEN/TOP mark must point upwards.
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111. |
Install cylinder head bolts
Note: Note tightening
sequence.
• |
Tighten 10x bolts 25 Nm + 90° +
90° + 90° + 45°
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112. |
Install exhaust manifold
• |
Position engine transport shackle
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Tighten 10x nuts 12 Nm + 12 Nm
Note: The nuts must be
tightened in two stages in accordance with the tightening
sequence
– |
Note tightening sequence.
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• |
Attach bracket for engine control unit wiring harness
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113. |
Fasten oil dipstick guide tube
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114. |
Install exhaust manifold heat shield
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115. |
Install oxygen sensor, mixture regulation, heated
• |
Apply assembly paste (white) to thread
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Tighten oxygen sensor 30 Nm
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117. |
Attach upper radiator hose
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118. |
Attach centre coolant hose
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120. |
Install intake manifold
• |
Attach brake servo vacuum line
– |
Connection must audibly engage
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121. |
Install right rear engine transport shackle
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122. |
Attach heating return hose
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123. |
Attach preheater hose for throttle valve module
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124. |
Install fuel distributor pipe
• |
Replace 4x injector seal rings
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• |
Connect fuel distributor pipe with injectors and engine
management wiring harness
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125. |
Attach wiring harness for engine management
• |
Connect 7x wiring harness plugs
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• |
Attach ground cable with bracket for knock sensor wiring
harness plug
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127. |
Attach fuel evaporation hose
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128. |
Install alternator shackle
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129. |
Install rear toothed belt cover
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130. |
Install toothed belt drive pulley
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131. |
Install toothed belt tension roller
• |
Detent lever (1) of toothed belt tension roller must engage in
guide web (2) of oil pump.
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• |
Bolt in bolt
Note: Adjust toothed
belt tension before tightening bolt.
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132. |
Install right engine bracket
• |
Insert bolts with locking compound (red)
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• |
Tighten bolts 65 Nm + 45° -
60°
Note: Note tightening
sequence (1 - 3).
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133. |
Install intake side toothed belt guide roller
Note: The toothed belt
guide roller with the greater diameter is installed at the intake
side.
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134. |
Install exhaust side toothed belt guide roller
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135. |
Install 2x camshaft sprockets
Note: Second person
required
• |
Tighten 2x bolts 50 Nm + 60° +
15°
– |
Counterhold camshafts at hexagonal section
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136. |
Fix camshaft sprockets in position.
• |
Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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• |
Use KM-852 (II)
– |
Turn the camshafts at hexagonal section
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137. |
Lock crankshaft
• |
Install crankshaft V-belt pulley bolt
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• |
Set crankshaft to mark.
– |
Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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138. |
Install toothed belt
Note: Note running
direction
• |
Position toothed belt
Note: Tensioned side
must be taut (I)
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139. |
Tension toothed belt
• |
Tension toothed belt tension roller
– |
Turn adjusting eccentric in direction of arrow (anticlockwise)
until pointer of the toothed belt tension roller is located just
before left stop
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• |
Fasten toothed belt tension roller bolt (1)
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141. |
Timing, Check
• |
Turn crankshaft in direction of engine rotation at the
crankshaft ribbed V-belt pulley bolt (720°)
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• |
Set crankshaft to mark.
– |
Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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• |
Use KM-852 (II)
– |
Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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143. |
Adjust toothed belt tension
• |
Release toothed belt tension roller
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• |
Turn adjustment eccentric in direction of arrow (clockwise)
until tension roller toothed belt pointer (1) is aligned with notch
mark (2).
– |
Adjust used toothed belts to the marking USED
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– |
Adjust new toothed belts to the marking NEW
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• |
Tighten toothed belt tension roller bolt 20 Nm
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144. |
Check toothed belt tension
• |
Pointer on the toothed belt tension roller and notch mark must
align.
– |
Adjust used toothed belts to the marking USED
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Adjust new toothed belts to the marking NEW
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145. |
Install lower part of toothed belt cover
• |
Clip to rear of toothed belt cover
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146. |
Install camshaft sensor
• |
Insert bolts with locking compound
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147. |
Install upper part of toothed belt cover
• |
Clip to rear of toothed belt cover
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148. |
Install cylinder head cover
• |
Apply sealant (1)
Note: Complete assembly
operations within 10 minutes
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• |
Attach engine vent hose
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• |
Clip in cable for mixture regulation heated oxygen sensor
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149. |
Install ignition module
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150. |
Install preheater line for throttle valve module
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151. |
Connect coolant temperature sensor wiring harness plug
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152. |
Connect camshaft sensor wiring harness plug
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153. |
Use MKM-883-1
Note: Second person
required
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154. |
Fasten MKM-883-1
Note: Observe
manufacturer's instructions
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155. |
Attach engine
• |
To right engine transport shackle
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• |
To front left engine transport shackle
Note: The front left
engine transport shackle is used only to stabilise the engine
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159. |
Release rear reaction member
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160. |
Remove front reaction member
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162. |
Lift engine
Note: Observe
manufacturer's instructions
• |
Carefully raise the engine approx. 40 mm on the timing side
with MKM-883-1
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164. |
Install oil pan
• |
Apply sealant
Note: Complete assembly
operations within 10 minutes
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• |
At cylinder block
– |
Tighten 12x bolts 10 Nm
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• |
Insert rear closure plug
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166. |
Lower engine
Note: When lowering pay
attention to the shift guide and rear reaction member
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168. |
Fasten rear reaction member
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169. |
Install front reaction member
• |
Tighten bolted connection 60 Nm
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170. |
Attach exhaust system
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171. |
Attach wiring harness for engine management
• |
Connect 2 wiring harness plugs
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172. |
Attach KM-6169
• |
Position KM-6169 on the left on the
front axle body
– |
Guide pin must be seated in bore in front axle body
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• |
Attach both right holders on the front axle body
– |
Guide pin must be seated in bore in front axle body
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173. |
Install support to KM-6169
• |
Adjust mount for support
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174. |
Adjust supports
• |
Transmission side
– |
Turn spindles until mounts are positioned at guide journals
free of play
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• |
Engine timing side
– |
Insert journal of the support in the bore of the cylinder block
free of play
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176. |
Clean thread on cylinder head.
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177. |
Install right engine damping block
• |
Fasten engine bracket adapter
– |
Tighten bolts 60 Nm + 30° -
45°
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• |
Fasten engine damping block
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180. |
Remove MKM-883-1
Note: Second person
required
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185. |
Fasten alternator
• |
Fasten alternator support
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186. |
Attach intake manifold support
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187. |
Install ribbed V-belt tensioner
• |
Tension ribbed V-belt tensioner with KM-913-A
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188. |
Attach crankshaft ribbed V-belt pulley
• |
Tighten bolt 95 Nm + 30° +
15°
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• |
Insert front closure plug
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189. |
Install ribbed V-belt
Note: Observe running
direction and installation position
• |
Slacken ribbed V-belt tensioner with KM-913-A
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190. |
Install ribbed V-belt cover
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191. |
Install right-hand air duct
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193. |
Attach front right wheel
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195. |
Fasten right front wheel.
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196. |
Install air cleaner housing
• |
Attach engine vent hose
|
• |
Clip in tank vent valve
|
• |
Connect 2 wiring harness plugs
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197. |
Install engine cover.
• |
Unscrew oil filler pipe cap
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• |
Screw on oil filler pipe cap
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199. |
Calibrate steering angle sensor
• |
Rotate the steering wheel one time from its right-hand to its
left-hand stop
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200. |
Program volatile memories
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201. |
Top up engine oil
• |
Start engine and allow to run until oil pressure telltale
extinguishes.
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• |
Check engine oil level, if necessary correct.
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202. |
Top up and bleed cooling system
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203. |
Reset service interval using TECH 2
Note: If the customer
decides to have ECOService - connect TECH2 and reprogram engine
control unit
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204. |
Fill out the service sticker
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