Remove and install cylinder head (Z 12 XE, Z 12
XEP, Z 14 XEP, with air conditioning, LHD)
Note: KM-6394 must be used as of model year 04 instead of
KM-6169-1 .
Remove
2. |
Disconnect battery
Note: In vehicles as of
model year 04 onwards with ESP - the steering angle sensor loses
its basic adjustment each time the battery is disconnected, and
must be recalibrated
|
3. |
Release upper front panelling
|
|
|
5. |
Release lower front panelling
• |
Disconnect wiring harness connector.
|
|
6. |
Detach front panelling
Note: Second person
required
• |
If present: Detach and seal headlamp washer system
high-pressure hose
|
|
|
|
Important: Angular dislocations
of the flexpipe as small as 5 to 10 degrees offset from the
intended installation position can cause damage and subsequent
complete failure of the flexpipe.
|
8. |
Detach front exhaust pipe (1) from catalytic converter
• |
Affix the front exhaust pipe to the vehicle underbody with
wire
|
|
9. |
Remove ribbed V-belt cover
|
|
|
10. |
Remove ribbed V-belt from compressor ribbed V-belt pulley
• |
Tension ribbed V-belt tensioner in direction of arrow with
KM-6131
|
|
|
|
11. |
Remove compressor
Note: The air
conditioning system remains closed
• |
Disconnect wiring harness plug (arrow)
|
|
|
|
12. |
Unclip wiring harness for engine management
|
|
|
13. |
Attach KM-6169-2 to transmission
|
|
|
14. |
Attach KM-6169 (1)
• |
Attach KM-6169 to left of front axle
body (arrows, illus. I)
– |
Guide pin must be seated in bore in front axle body
|
|
• |
Attach both right holders on the front axle body (arrows,
Illus. II).
– |
Guide pin must be seated in bore in front axle body (arrow,
Fig. III)
|
|
|
|
|
|
15. |
Install support
• |
An KM-6169
– |
Adjust bracket (2) for support
|
|
|
16. |
Adjust supports
• |
Transmission side
– |
Turn spindles until mounts (3) are positioned at guide journals
free of play
|
|
• |
Engine timing side
– |
Insert journal of the support in the bore of the cylinder block
without play (arrow)
|
|
|
|
17. |
Loosen right engine bracket
|
|
|
19. |
Drain coolant
• |
Place collecting basin underneath.
|
• |
Open drain bolt (arrow)
|
|
|
|
21. |
Remove air cleaner housing (1)
• |
Disconnect 2 wiring harness plugs
– |
Hot film mass air flow sensor (3), tank vent valve (2)
|
|
• |
Remove suction pipe (4)
– |
Detach engine vent hose (5)
|
|
• |
For Z 12 XEP, Z 14 XEP: detach air intake hose
|
|
|
|
22. |
Detach throttle valve module preheater return hose (1)
|
23. |
Remove throttle valve module preheater feed hose (1)
|
24. |
Detach heater return hose (2) from coolant pump
|
25. |
Detach heater return hose from exhaust gas recirculation
coolant flange
|
|
|
26. |
Detach brake servo vacuum line (4)
|
27. |
Pull fuel evaporation hose (3) from intake manifold
|
|
|
Important: Observe safety
precautions and national regulations
|
28. |
Release fuel pressure with KM-J-34730-91
• |
Unscrew test connection protective cap (2) from fuel rail
(1)
Note: Test connection
is on top of fuel rail in Z 12 XEP and Z 14 XEP
|
|
|
|
29. |
Detach fuel rail (arrow) with KM-796-A
|
|
|
30. |
Remove intake pipe (1)
|
|
|
31. |
Remove exhaust manifold gasket or replace exhaust manifold
Remove exhaust manifold gasket
|
Z 12 XE, Z 14 XEP with air conditioning
|
Replace exhaust manifold
|
Z 12 XEP, Z 14 XEP Combo
|
|
32. |
Remove oil filter housing cover
|
33. |
Remove oil filter housing (1)
• |
Place another collecting basin underneath
|
|
34. |
Remove upper radiator hose
|
|
|
35. |
Detach coolant connection
|
|
|
36. |
Remove right engine bracket
• |
Remove right engine damping block
|
• |
Remove engine bracket
– |
Unscrew 2 bolts (arrows)
|
|
|
37. |
Remove ribbed V-belt
Note: Mark running
direction.
|
38. |
Remove coolant pump ribbed V-belt pulley
|
|
|
|
39. |
Remove wiring harness for engine management
• |
For Z 12 XEP, Z 14 XEP: remove fuel rail cover
|
• |
Disconnect 12 wiring harness plugs
– |
Oil pressure switch (5), coolant temperature sensor (6),
camshaft sensor (1), injectors (2), throttle valve adjuster (3),
engine control unit (7), combination plug (8), exhaust gas
recirculation valve (9), ignition module (4)
|
|
• |
Detach 3 ground cables (arrows)
|
• |
Set wiring harness to one side
|
|
|
40. |
Remove timing case fastening bolts
• |
Timing case
– |
Unscrew 5 bolts (arrows)
|
|
|
|
|
41. |
Remove ignition module
• |
Remove ignition module cover
|
• |
Extract using KM-6009 (1)
Note: Do not tilt
|
|
42. |
Remove cylinder head cover
• |
Detach engine vent hose
|
|
|
|
|
43. |
Set no.1 cylinder to TDC
• |
Remove crankshaft bearing bridge closure bolt (1)
|
• |
Insert KM-952 (2)
Note: Mark on
crankshaft belt pulley (4) must line up with lug (3) on timing
case
– |
Turn crankshaft uniformly until KM-952 engages
|
|
|
|
|
44. |
Insert KM-953 (1)
Note: KM-953 must engage in camshaft groove
|
|
46. |
Lock chain tensioner
• |
Remove closure bolt (1)
|
• |
Load intake camshaft in direction of arrow via hexagonal
section using an open-ended spanner
|
|
|
|
|
47. |
Remove sliding rail (1)
|
48. |
Detach camshaft sprockets
• |
Unscrew 2 bolts (2)
– |
Counterhold camshafts at hexagonal section (3)
|
|
• |
Remove phase sensor disc
|
|
|
49. |
Remove cylinder head bolts
Note: Undo bolts in
order shown
|
50. |
Remove cylinder head
Note: Second person
required
• |
Guide chain tensioner past tensioning rail
|
• |
Place cylinder head on wooden blocks
|
• |
Remove cylinder head gasket
|
|
|
|
Install
|
51. |
Detach timing case gasket
• |
Cut through elastomer sealing lips (dimension I and II) from
inside outwards flush to cylinder block
|
• |
Carefully bend gasket at designated break points (arrows)
|
|
52. |
Clean sealing surfaces
• |
Cylinder block, cylinder head, timing case, exhaust manifold,
oil filter housing, thermostat housing, cylinder head cover
|
|
|
53. |
Inspect components
Note: If cylinder head
is to be checked and overhauled : Remove all outer attaching parts
from cylinder head.
• |
Cylinder block, cylinder head, timing case, exhaust manifold,
oil filter housing, thermostat housing, cylinder head cover
|
|
54. |
Check for plane surface
• |
Cylinder head, cylinder block
|
• |
With straightedge, feeler gauge
|
|
|
|
|
55. |
Replace cylinder head gasket
• |
Cut off protruding elastomer (dimension I) on timing case
side
|
|
|
|
56. |
Apply sealant (dimension I = 2 mm)
Note: Complete assembly
operations within 10 minutes
• |
Attach cylinder head gasket
– |
OBEN/TOP mark must point upwards.
|
|
|
|
|
57. |
Fit timing case upper gasket (1)
• |
Apply sealant (dimension I = 2 mm)
|
• |
Insert 2 upper fastening bolts into timing case (arrows)
Note: The fastening
bolts are used to fix the upper timing case gasket in position
|
• |
Attach gasket
Note: Push on in
vicinity of sealant
|
|
|
58. |
Attach cylinder head
Note: Second person
required
• |
Guide KM-955-1 through aperture in
timing case
|
• |
Guide chain tensioner past tensioning rail
|
• |
Insert pin in guide rail
|
|
59. |
Fasten cylinder head
• |
Replace cylinder head bolts
– |
Screw in bolts by several threads
|
|
• |
Attach timing case.
– |
Tighten 3 bolts (1) 8 Nm
|
|
• |
Position cylinder head by tapping with rubber mallet in
direction of timing case
|
• |
Tighten 12 cylinder head bolts 25 Nm +
60° + 60° + 60°
– |
Note tightening sequence.
|
|
|
|
|
60. |
Install timing case fastening bolts
- Undo lower 3 bolts of cylinder head again (previously installed
bolts)
- Coolant pump
- Timing case
- Tighten 5 bolts (arrows) 8
Nm
|
|
|
|
61. |
Adjust camshafts
• |
Insert KM-953 (1)
– |
"Turn" the camshafts at hexagonal section (arrows)
|
|
|
|
62. |
Attach camshaft sprockets
• |
Attach intake camshaft sprocket with phase sensor disc (2)
– |
Bolt in bolt
Note: It must be
possible to rotate phase sensor disk by hand
|
|
• |
Attach exhaust camshaft sprocket
|
|
64. |
Remove KM-955-1
• |
Tighten chain tensioner closure bolt 50
Nm
|
|
65. |
Attach KM-954
• |
Rotate phase sensor disk until KM-954
(1) can be attached to timing case
|
|
|
|
66. |
Fasten camshaft sprockets
Note: Tightening torque
of 10 Nm is used to secure the
camshaft sprockets and the phase sensor disk
• |
Tighten 2 bolts (2) 10 Nm
Note: First tighten
intake camshaft sprocket bolt
– |
Counterhold camshafts at hexagonal section (1)
|
|
|
67. |
Remove retaining tools
Note: Retaining tools
must not be used for counterholding
• |
KM-952 , KM-953 , KM-954
|
|
68. |
Fasten camshaft sprockets
Note: Second person
required
• |
Tighten 2 bolts (2) 50 Nm +
60°
Note: First tighten
intake camshaft sprocket bolt
– |
Counterhold camshafts at hexagonal section
|
|
|
|
|
70. |
Remove retaining tools
• |
KM-952 , KM-953 , KM-954
|
|
71. |
Attach cylinder head cover (1)
• |
Renew gasket (2) and seal rings
|
• |
Apply sealant (dimension I = 2 mm)
Note: Complete assembly
operations within 10 minutes
|
• |
Attach engine vent hose
|
|
|
|
72. |
Attach ignition module
• |
Attach ignition module cover
|
|
73. |
Attach wiring harness for engine management
• |
Connect wiring harness for engine management
– |
Connect 14 wiring harness plugs
|
– |
Screw on 3 ground cables
|
|
• |
For Z 12 XEP, Z 14 XEP: attach fuel rail cover
|
|
74. |
Attach coolant pump ribbed V-belt pulley
|
75. |
Install ribbed V-belt
Note: Note running
direction
• |
Tension ribbed V-belt tensioner with KM-6131
|
• |
Release ribbed V-belt tensioner
|
|
76. |
Fasten coolant pump ribbed V-belt pulley
|
78. |
Fit compressor
• |
Connect wiring harness plug
|
|
79. |
Install right engine bracket
• |
Tighten 2 upper bolts 60 Nm
|
• |
Fasten engine damping block
|
|
80. |
Install coolant connection
|
81. |
Attach upper radiator hose
|
82. |
Install oil filter housing
• |
Attach oil filter housing cover
|
|
83. |
Remove exhaust manifold gasket or replace exhaust manifold
Remove exhaust manifold gasket
|
Z 12 XE, Z 14 XEP with air conditioning
|
Replace exhaust manifold
|
Z 12 XEP, Z 14 XEP Combo
|
|
85. |
Close coolant drain bolt
|
86. |
Fasten right engine bracket
• |
Tighten lower bolt 60 Nm
|
|
90. |
Attach closure bolt of crankshaft bearing bridge
|
91. |
Fasten engine management wiring harness
|
92. |
Install ribbed V-belt
Note: Note running
direction
• |
Tension ribbed V-belt tensioner with KM-6131
|
• |
Release ribbed V-belt tensioner
|
|
93. |
Fasten coolant pump ribbed V-belt pulley
|
94. |
Attach exhaust system
• |
Connect oxygen sensor (catalytic converter control) wiring
harness plug.
|
|
95. |
Install ribbed V-belt cover
|
97. |
Position front panelling
Note: Second person
required
• |
Install high-pressure headlamp washer hose
|
|
98. |
Fasten lower front panelling
• |
Connect wiring harness plug
|
|
100. |
Fasten upper front panelling
|
102. |
Attach brake servo vacuum line
• |
Connection must audibly engage
|
|
103. |
Attach fuel evaporation hose
|
104. |
Attach fuel line
• |
Attach fuel line
– |
Connection must audibly engage
|
|
|
105. |
Attach heater return hose
|
106. |
Attach heater supply hose
|
107. |
Install throttle valve module preheater supply hose
|
108. |
Attach throttle valve module preheater return hose
|
109. |
Install air cleaner housing
• |
For Z 12 XEP, Z 14 XEP: attach air intake hose
|
• |
Attach engine vent hose
|
• |
Clip in tank vent valve
|
• |
Connect 2 wiring harness plugs
|
|
111. |
Calibrate steering angle sensor
• |
Rotate the steering wheel one time from its right-hand to its
left-hand stop
|
|
112. |
Top up and bleed cooling system – see operation "Cooling
System, Top up and Bleed"
|
113. |
Check engine oil level and correct if necessary
|
114. |
Program volatile memory
|
|