J 312315 Valve Stem Seals, Replace (Z 18 XE, with
Air Conditioning, LHD)
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.
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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)
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Disconnect 2 wiring harness plugs
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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
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Unscrew 3 bolts (arrows)
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Unclip from rear toothed belt cover
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7. |
Remove right-hand air duct
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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
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Tension ribbed V-belt tensioner in direction of arrow with
KM-913-A (2)
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15. |
Remove ribbed V-belt tensioner
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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
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Prise front closure plug out of oil pan
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17. |
Release lower part of toothed belt cover
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Unclip from rear toothed belt cover
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20. |
Disconnect camshaft sensor wiring harness plug (1)
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21. |
Remove lower part of toothed belt cover
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Unclip from rear toothed belt cover
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22. |
Remove camshaft sensor (2)
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23. |
Set 1st cylinder to TDC of combustion stroke
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Install crankshaft V-belt pulley bolt
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Set crankshaft to mark.
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Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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Fix camshaft sprockets in position.
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Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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24. |
Remove toothed belt
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Release toothed belt tension roller (IV)
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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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25. |
Remove ignition module
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Disconnect wiring harness plug (2)
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Extract using KM-6009 (1)
Note: Do not tilt
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26. |
Release preheater line - throttle valve module (1)
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Disconnect coolant temperature sensor wiring harness plug
(4)
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Unclip wiring harness of mixture regulation heated oxygen
sensor (3)
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27. |
Remove cylinder head cover
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Detach engine vent hose (2)
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29. |
Remove exhaust camshaft sprocket
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Remove bolt
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Counterhold camshaft at hexagonal section
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30. |
Remove intake camshaft sprocket
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Remove bolt
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Counterhold camshaft at hexagonal section
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31. |
Release rear toothed belt cover
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32. |
Loosen upper rear toothed belt cover
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33. |
Remove exhaust camshaft
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Remove camshaft bearing cap
Note: Note
identification
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Release camshaft bearing caps in stages, working in a spiral
pattern from the outside inwards
Note: Camshaft must be
evenly released from the bearing seats
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Remove camshaft seal ring
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34. |
Remove 8x hydraulic valve lifters (2) with KM-845 (1)
Note: Observe
allocation.
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35. |
Remove intake camshaft
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Remove camshaft bearing cap
Note: Note
identification
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Release camshaft bearing caps in stages, working in a spiral
pattern from the outside inwards
Note: Camshaft must be
evenly released from the bearing seats
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Remove camshaft seal ring
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36. |
Remove 8x hydraulic valve lifters with KM-845
Note: Observe
allocation.
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37. |
Remove 4x spark plugs with KM-194-E
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39. |
Close coolant drain bolt
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40. |
Apply positioning marks to toothed belt drive gear
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180° offset to no.1 cylinder TDC mark
(Zünd-OT-Zylinder-1) (arrows)
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43. |
Assemble automatic valve spring compressor
Note: Observe
manufacturer's instructions
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Adjust supports
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Adjust support heads (1) so that they are centred on support
feet (2) and tighten
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Assemble lever arm with joint and removal head
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Assemble installation kit MKM-6089-200
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Insert thrust piece 5b (3)
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44. |
Attach automatic valve spring compressor
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Attach supports to camshaft bearing cap positions 1 and 4
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Slide installation shaft into supports
Note: Align
installation shaft so that it is centred on spark plug bore
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Install lever arm (1)
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Removal head (2) must face intake side
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Secure installation shaft
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45. |
Install compressed air adapter (3)
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Screw into spark plug thread of 1st cylinder
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Apply compressed air to 1st cylinder
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46. |
Remove 2x cylinder no.1 intake valve springs
Note: Do not use
magnetised tool.
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Carefully push valve spring down with lever arm
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Removal head must be vertically above the valve stem
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Remove valve keepers, valve head, valve spring
Note: Observe
allocation.
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47. |
Replace 2x valve stem seals
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Detach using KM-840 (1)
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Attach new valve stem seal to valve stem
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Drive in to stop using KM-835-A
(2)
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48. |
Install intake valve springs for 1st cylinder
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Insert valve spring, valve head
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Insert valve keepers (1) in assembly head
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Slide clamping sleeve (2) in direction of lever arm mount
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Insert valve keepers with taper facing the valve.
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Push clamping sleeve towards valve
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Attach assembly head to lever arm
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Carefully push valve spring down with lever arm
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Assembly head must be vertically above the valve stem
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The valve keepers must audibly engage
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49. |
Check installation position
Note: Do not make 2nd
attempt without checking that both valve keepers are in the
assembly head.
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Check seat of valve keepers
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Check that compressed air is being applied
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50. |
Transfer lever arm
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Install lever arm
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Removal head must face exhaust side
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51. |
Remove 2x cylinder no.1 exhaust valve springs
Note: Do not use
magnetised tool.
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Carefully push valve springs downwards
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Removal head (1) must be vertically above the valve stem
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Remove valve keepers, valve head, valve spring
Note: Observe
allocation.
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52. |
Replace 2x valve stem seals
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Detach using KM-840 (1)
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Attach new valve stem seal to valve stem
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Drive in to stop using KM-835-A
(2)
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53. |
Install exhaust valve springs for 1st cylinder
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Insert valve springs, valve head
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Insert valve keepers in assembly head
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Push clamping sleeve towards lever arm mount
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Insert valve keepers with taper facing the valve.
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Push clamping sleeve towards valve
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Attach assembly head to lever arm
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Carefully push valve spring down with lever arm
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Assembly head must be vertically above the valve stem
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The valve keepers must audibly engage
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54. |
Check installation position
Note: Do not make 2nd
attempt without checking that both valve keepers are in the
assembly head.
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Check seat of valve keepers
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Check that compressed air is being applied
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55. |
Transfer compressed air adapter
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Interrupt compressed air feed
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Unscrew from spark plug thread of 1st cylinder
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Screw into spark plug thread of 4th cylinder
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Apply compressed air to 4th cylinder
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56. |
Transfer lever arm
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Loosen installation shaft
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Secure installation shaft
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57. |
Replace 4x valve stem seals for cylinder no. 4
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58. |
Interrupt compressed air feed
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61. |
Set 3rd cylinder to TDC of combustion stroke
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Turn crankshaft evenly (180°)
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Toothed belt drive gear positioning mark must align with mark
on rear toothed belt cover.
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64. |
Transfer automatic valve spring compressor
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Transfer supports to camshaft bearing cap positions 1 and 5
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Slide installation shaft into supports
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Align installation shaft so that it is centred on spark plug
bore
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Install lever arm
Note: Removal head must
face intake side
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Secure installation shaft
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65. |
Transfer compressed air adapter
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Unscrew from spark plug thread of 4th cylinder
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Screw into spark plug thread of 2nd cylinder
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Apply compressed air to 2nd cylinder
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66. |
Replace 4x valve stem seals for cylinder no. 2
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67. |
Transfer compressed air adapter
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Interrupt compressed air feed
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Unscrew from spark plug thread of 2nd cylinder
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Screw into spark plug thread of 3rd cylinder
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Apply compressed air to 3rd cylinder
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68. |
Replace 4x valve stem seals for cylinder no. 3
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69. |
Interrupt compressed air feed
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70. |
Detach automatic valve spring compressor
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71. |
Remove compressed air adapter
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Install
72. |
Inspect components
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Camshafts, camshaft bearing caps, hydraulic valve lifters,
cylinder head, ribbed V-belt, ribbed V-belt tensioner, ribbed
V-belt pulleys, toothed belt drive, spark plugs
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73. |
Install spark plugs
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Tighten 4x with KM-194-E , 25 Nm
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76. |
Position crankshaft
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Set crankshaft to 60° before no.1 cylinder TDC of
combustion stroke
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79. |
Insert 8x hydraulic valve lifters
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Coat sliding surfaces with engine oil
Note: Observe
allocation.
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80. |
Install intake camshaft
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Coat sliding surfaces with engine oil
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Apply sealant in the area of the camshaft seal ring
(arrows)
Note: Do not apply
sealant in vicinity of oil channels. Complete installation work
within 10 minutes.
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Insert camshaft, camshaft bearing cap
Note: Observe
identification and allocation
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Tighten 10x bolts for camshaft bearing caps 8 Nm
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Tighten in stages, working in a spiral pattern from the inside
outwards
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81. |
Insert 8x hydraulic valve lifters
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Coat sliding surfaces with engine oil
Note: Observe
allocation.
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82. |
Install exhaust camshaft
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Coat sliding surfaces with engine oil
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Apply sealant in the area of the camshaft seal ring
(arrows)
Note: Do not apply
sealant in vicinity of oil channels. Complete installation work
within 10 minutes.
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Insert camshaft, camshaft bearing cap
Note: Observe
identification and allocation
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Tighten 10x bolts for camshaft bearing caps 8 Nm
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Tighten in stages, working in a spiral pattern from the inside
outwards
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83. |
Install intake camshaft seal ring
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Coat seal lip with grease
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Place seal ring on camshaft journal
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Install camshaft seal ring
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With KM-422 (1), bolt and camshaft
sprocket washer
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84. |
Install intake camshaft seal ring
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Coat seal lip with grease
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Place seal ring on camshaft journal
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Install camshaft seal ring
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With KM-422 , bolt and camshaft
sprocket washer
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85. |
Fasten upper rear toothed belt cover
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86. |
Install camshaft sprocket on exhaust side
Note: Attach camshaft
sprocket with cylinder recognition to exhaust camshaft.
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Attach KM-6347 , KM-956-1
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Tighten bolt 50 Nm + 60° +
15°
Note: Second person
required
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Remove KM-6347 , KM-956-1
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87. |
Install camshaft sprocket on the intake side
Note: Attach camshaft
sprocket with cylinder recognition to exhaust camshaft.
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Attach KM-6347 , KM-956-1
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Tighten bolt 50 Nm + 60° +
15°
Note: Second person
required
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Remove KM-6347 , KM-956-1
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88. |
Fix camshaft sprockets in position.
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Marks must be opposite one another and aligned with the top
edge of the cylinder head.
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Use KM-852
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Turn the camshafts at hexagonal section
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89. |
Put toothed belt in place
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Position toothed belt
Note: Tensioned side
(I) must be taut.
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90. |
Tension toothed belt
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Tension toothed belt tension roller
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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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92. |
Timing, Check
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Turn crankshaft in direction of engine rotation at the
crankshaft ribbed V-belt pulley bolt (720°)
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Set crankshaft to mark.
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Marks on drive gear toothed belt and rear toothed belt cover
must align (III).
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Use KM-852 (II)
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Marks must be opposite one another and aligned with the top
edge of the cylinder head (I)
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94. |
Adjust toothed belt tension
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Release toothed belt tension roller
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Turn adjustment eccentric in the direction of the arrow
(clockwise) until pointer (1) of toothed belt tension roller is
aligned with the appropriate notch mark
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Adjust used toothed belts to the marking USED
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Adjust new toothed belts to the marking NEW (2)
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Tighten toothed belt tension roller bolt 20 Nm
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95. |
Check toothed belt tension
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Pointer on the toothed belt tension roller and notch mark must
align.
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Adjust used toothed belts to the marking USED
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Adjust new toothed belts to the marking NEW
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96. |
Clean threads
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Camshaft sensor to cylinder head
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98. |
Install camshaft sensor
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Insert bolts with locking compound (red)
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99. |
Install lower part of toothed belt cover
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Clip to rear of toothed belt cover
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100. |
Install upper part of toothed belt cover
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Clip to rear of toothed belt cover
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101. |
Install cylinder head cover
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Apply sealant (1)
Note: Complete assembly
operations within 10 minutes
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Attach engine vent hose
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102. |
Fasten preheater line - throttle valve module
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Connect coolant temperature sensor wiring harness plug
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Clip in wiring harness of mixture regulation heated oxygen
sensor
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103. |
Connect wiring harness plug from camshaft sensor
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104. |
Install ignition module
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Connect wiring harness plug
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106. |
Install ribbed V-belt tensioner
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Tension ribbed V-belt tensioner with KM-913-A
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107. |
Attach crankshaft ribbed V-belt pulley
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Tighten bolt 95 Nm + 30° +
15°
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Insert front closure plug
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108. |
Install ribbed V-belt
Note: Observe running
direction and installation position
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Slacken ribbed V-belt tensioner with KM-913-A
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109. |
Install ribbed V-belt cover
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110. |
Install right-hand air duct
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112. |
Attach front right wheel
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114. |
Fasten right front wheel.
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115. |
Install air cleaner housing
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Attach engine vent hose
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Clip in tank vent valve
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Connect 2 wiring harness plugs
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116. |
Install engine cover.
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Unscrew oil filler pipe cap
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Screw on oil filler pipe cap
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118. |
Calibrate steering angle sensor
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Rotate the steering wheel one time from its right-hand to its
left-hand stop
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119. |
Program volatile memories
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