Special tool
 | Engine Lift Bracket 303-122 (21-068A) |
 | Bolt Tightening Angle Gauge 303-174 (21-540) |
 | Engine support crossmember 303-290A (21-140A) |
 | Adapter for 303-290A (21-140) 303-290-01 (21-140-01) |
 | Adapter for 303-290A (21-140) 303-290-02 (21-140-02) |
 | Adapter for 303-290A (21-140) 303-290-03A (21-140-03A) |
 | Clamp removal/installation tool 303-397 (24-003) |
| Name | Specification |
| Motor oil | WSS-M2C912-A1 |
| Loctite 7070 | |
| ISO 4113 Lubrication |
Removal
All cars
1.
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
WARNING: Do not perform any repairs to the fuel injection system without first relieving the fuel pressure to zero and ensuring that the fuel temperature is below 30°C. Failure to follow these instructions may result in personal injury.
WARNING: Do not carry out any repairs to the fuel injection system while the engine is running. The fuel pressure in the system is approximately 1600 bar. Failure to follow these instructions may result in personal injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, absolute cleanliness is especially important when working with these components. Always plug any open ports or lines.
CAUTION: Before performing any repairs to fuel injection system components, always clean them to prevent foreign material from entering the components.
Using the Datalogger function of the Worldwide Diagnostic System (WDS), ensure that the fuel pressure is reset to zero and the fuel temperature is below 30°C.
2. Remove the battery and battery tray. For additional information, refer to Section 414-01.
3. Drain the coolant from the cooling system. Refer to Section 303-03 for additional information.
4. Remove the timing belt. For more information, refer to the Timing Belt chapter in this section.
5. Remove the pulley from the camshaft.
6. Disconnect the rear timing belt cover (the engine is shown removed for clarity).
Cars manufactured up to 04.2001.
7. Install the front engine mount.
Cars manufactured since 04.2001.
8. Install the front engine mount.
All cars
9. Remove the special tools.
10. Remove the air cleaner. Refer to Section 303-12 for additional information.
11. Remove the air cleaner outlet pipe.
12. Disconnect the vacuum hose from the turbocharger vacuum diaphragm block.
13. Disconnect the exhaust gas recirculation (EGR) vacuum hose from the EGR valve.
14. Disconnect the EGR vacuum hose.
15. Disconnect the electronic vacuum control valve support bracket from the intake manifold and place it aside.
16. Remove the oil catch can.
17. Install the camshaft bearing cap nuts.
18. Raise and support the vehicle. Refer to Section 100-02 for additional information.
19. Disconnect the catalytic converter from its bracket.
20. Disconnect the feed and return oil lines from the turbocharger.
- 1. Unscrew the bolt securing the supply oil line.
- 2. Unscrew the return oil line mounting bolts.
- Discard the gaskets as they are no longer needed.
21. Lower the vehicle.
22. Disconnect the oil pressure switch connector.
23. Disconnect the engine wiring harness plug connector.
24. Remove the positive crankcase ventilation (PCV) housing.
25. Disconnect the high pressure line from the power steering pump. Allow the fluid to drain into a suitable container.
26. Disconnect the power steering high pressure line bracket from the timing belt cover stud.
27. Disconnect the power steering high pressure line bracket from the lifting eye.
28. Disconnect the power steering high pressure line from the bracket and place it aside.
29. Disconnect the glow plug power supply wire from the glow plug wire terminal block.
30. Disconnect the glow plug wire terminal block.
31. Disconnect the oil level indicator dipstick and secure it to the side.
32. Disconnect the vacuum line from the brake booster vacuum pump.
33. Using the special tool, disconnect the upper coolant hose from the thermostat housing.
34. Remove the thermostat housing. Discard the gasket as it is no longer needed.
35. Disconnect the power steering fluid reservoir and secure it to the side. Allow the fluid to drain into a suitable container.
36. Disconnect the exhaust manifold from the catalytic converter.
Cars with EGR cooler
37. Using the special tool, disconnect the upper coolant hose from the EGR cooler.
All cars
38. Clean the area around the fuel rail, high pressure fuel supply lines and adjacent areas. For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
39.
CAUTION: To prevent fuel from splashing when disconnecting the fuel return line, cover the fuel injectors with a lint-free material. Failure to follow this instruction may result in personal injury.
Disconnect the fuel return line from the fuel injectors and install plugs in the fuel injector return ports.
40. Disconnect the fuel injector connectors and cover them with a lint-free material to prevent contamination from the cleaning fluid.
41.
NOTE: Mark the orientation of the clamps to ensure they are installed in exactly the same position.
Remove the high pressure fuel supply line clamp.
42.
CAUTION: The tool used to loosen the high pressure fuel supply line connections must be positioned at the top of the connection as this is where most of the material is located. Failure to follow this instruction may result in damage to the nipple connection.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel injector cone when disconnecting the nipple connection.
NOTE: While maintaining pressure on the high pressure fuel supply line, use a vacuum cleaner to remove foreign material from the lines and connections.
Disconnect the high pressure fuel supply lines from the fuel injectors.
43. Cover the generator with a lint-free material to prevent contamination from the cleaning fluid.
44.
NOTE: Cover the plug connector with a lint-free cloth to prevent contamination from the cleaning fluid.
Disconnect the high fuel pressure sensor connector.
45.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel rail cone when disconnecting the nipple connection.
NOTE: While maintaining pressure on the high pressure fuel supply line, use a vacuum cleaner to remove foreign material from the lines and connections.
Remove the high pressure fuel supply lines.
- Install plugs into the open threaded ports of the fuel injectors and fuel rail.
- Discard the high pressure fuel supply lines as they are no longer needed.
46. Remove the high pressure fuel supply line bracket.
47.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipples in contact with the cones of the high pressure fuel pump and fuel rail when disconnecting the nipple connections.
NOTE: While maintaining pressure on the high pressure fuel supply line, use a vacuum cleaner to remove foreign material from the lines and connections.
Remove the high-pressure fuel supply line. Install plugs in the open threaded ports of the high-pressure fuel pump and fuel rail.
48.
NOTE: Mark the orientation of the clamp to ensure it is installed in the exact same position.
Remove the high pressure fuel supply line clamp. Discard the high pressure fuel supply line as it is no longer needed.
49. Remove the lower fuel manifold bracket mounting bolt.
50. Remove the fuel rail bracket and fuel rail.
51.
CAUTION: Remove the cylinder head bolts in the sequence shown.
Remove the cylinder head bolts. Discard the bolts as they are no longer needed.
52. Using a special tool, remove the cylinder head. Discard the gasket as it is no longer needed.
Installation
All cars
1.
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, absolute cleanliness is especially important when working with these components. Always plug any open ports or lines.
CAUTION: To prevent foreign material from entering the fuel system components, always clean them before performing any repairs to such components.
Clean the mating surfaces of the cylinder head and cylinder block using Loctite 7070.
2. Inspect the cylinder head for mating surface distortion. Refer to Section 303-00 for additional information.
3.
CAUTION: The thickness of the new cylinder head gasket must match the thickness of the "old" one (marked with holes/teeth).
NOTE: Marked "TOP/OBEN".
Install a new cylinder head gasket.
4.
NOTE: The pistons must not be at top dead center. Make sure the special tool fits into the grooves on the ends of the camshafts.
Install the cylinder head on the cylinder block using the special tool during installation. Remove the special tool.
5.
CAUTION: Use new, non-greased cylinder head bolts.
Tighten the cylinder head bolts in four stages.
- Using the special tool, tighten the bolts in the sequence shown
- Stage 1: 20 Nm
- Stage 2: 54 Nm
- Stage 3: 90 degrees
- Stage 4: Short bolts: 70 degrees, Long bolts: 90 degrees
6.
NOTE: Do not tighten the fuel rail bracket bolts at this stage.
Install the fuel rail bracket and fuel rail.
7.
NOTE: Do not tighten the fuel rail bracket bolt at this stage.
Install the lower fuel rail bracket mounting bolt.
8.
NOTE: Use new high pressure fuel supply line nipples.
Lubricate the high pressure fuel supply line connection threads with clean ISO 4113 grease supplied in the high pressure fuel supply line replacement parts kit.
9.
CAUTION: Do not allow the mating ends of the high pressure fuel supply line nipple joint to collide, as this may cause damage to the fuel line and foreign material to enter the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel injector cone while hand tightening the nipple.
NOTE: The yellow flange on the high pressure fuel supply line is located on the injector side and the blue flange is located on the fuel rail side.
Connect the high pressure fuel supply lines of cylinders No.1 and 4 to the fuel injectors.
10.
CAUTION: Do not allow the mating ends of the high pressure fuel supply line nipple joint to collide, as this may cause damage to the fuel line and foreign material to enter the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel injector cone while hand tightening the nipple.
Connect the high pressure fuel supply lines of cylinders No.1 and 4 to the fuel rail.
11.
NOTE: Ensure that the clamp is installed in the same position as it was before removal.
Install the clamp on the high pressure fuel supply line.
12.
NOTE: Use a new high pressure fuel supply line connection.
Lubricate the high pressure fuel supply line connection threads with clean ISO 4113 grease supplied in the high pressure fuel supply line replacement parts kit.
13.
CAUTION: Do not allow the mating ends of the high pressure fuel supply line nipple joint to collide, as this may cause damage to the fuel line and foreign material to enter the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connection at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel injector cone while hand tightening the nipple.
NOTE: The yellow flange on the high pressure fuel supply line is located on the injector side and the blue flange is located on the fuel rail side.
Install the high pressure fuel supply line.
14.
CAUTION: Do not allow the mating ends of the high pressure fuel supply line nipple joint to collide, as this may cause damage to the fuel line and foreign material to enter the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel injector cone while hand tightening the nipple.
NOTE: The yellow flange on the high pressure fuel supply line is located on the injector side and the blue flange is located on the fuel rail side.
Connect the high pressure fuel supply lines of cylinders No.2 and 3 to the fuel injectors.
15.
CAUTION: Do not allow the mating ends of the high pressure fuel supply line nipple joint to collide, as this may cause damage to the fuel line and foreign material to enter the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel injector cone while hand tightening the nipple.
Connect the high pressure fuel supply lines of cylinders No.2 and 3 to the fuel manifold.
16. Connect the fuel return line to the fuel injectors.
17.
NOTE: Ensure that the clamps are installed in the same position from which they were removed.
Install the high pressure fuel supply line clamps.
18. Install the high pressure fuel supply line bracket.
19. Install the fuel rail bracket and fuel rail.
20. Install the lower fuel rail bracket mounting bolt.
21. Tighten the high pressure fuel supply lines of cylinders No.1 and 4 to the fuel injectors.
22. Tighten the high pressure fuel supply lines of cylinders No.1 and 4 to the fuel rail.
23. Install the high pressure fuel supply line.
24. Tighten the high pressure fuel supply lines of cylinders No.2 and 3 to the fuel injectors.
25. Tighten the high pressure fuel supply lines of cylinders No.2 and 3 to the fuel rail.
Cars with EGR cooler
26. Using the special tool, connect the upper coolant hose to the EGR cooler.
All cars
27. Connect the exhaust manifold to the catalytic converter.
28. Secure the power steering fluid reservoir.
29. Connect the high pressure fuel sensor connector.
30.
NOTE: Use a new gasket.
Install the thermostat housing.
31. Using the special tool, connect the upper coolant hose to the thermostat housing.
32. Connect the vacuum line to the brake booster vacuum pump.
33. Connect the oil level indicator dipstick.
34. Connect the glow plug wire terminal block.
35. Connect the glow plug power wire to the glow plug wire terminal block.
36. Connect the power steering high pressure line to the bracket.
37. Connect the power steering high pressure line bracket to the lifting eye.
38. Connect the power steering high pressure line bracket to the timing belt cover stud.
39. Connect the high pressure line to the power steering pump.
40. Connect the engine wiring harness plug connector.
41.
NOTE: Install the clamp at a 45 degree angle to horizontal.
Install the PCV housing.
42. Connect the oil pressure switch plug connector.
43. Raise and support the vehicle. Refer to Section 100-02 for additional information.
44.
NOTE: Use new gaskets.
Connect the supply and return oil lines to the turbocharger.
- 1. Install the return oil line mounting bolt.
- 2. Install the supply oil line mounting bolts.
45. Connect the catalytic converter to the appropriate bracket.
46. Lower the car.
47. Remove the bearing cap nuts.
48. Install the oil catch can.
49. Attach the electronic vacuum control valve support bracket to the intake manifold and position it aside.
50. Connect the EGR vacuum hose.
51. Connect the EGR vacuum hose to the EGR valve.
52. Connect the vacuum hose to the turbocharger vacuum diaphragm block.
53. Install the air cleaner outlet pipe.
54. Install the air cleaner. Refer to Section 303-12 for additional information.
55. Install special tools.
Cars manufactured up to 04.2001.
56. Remove the front engine mount.
Cars manufactured since 04.2001.
57. Remove the front engine mount.
All cars
58. Install the rear timing belt cover (engine shown removed for clarity).
59.
NOTE: Do not tighten the camshaft pulley bolt at this stage.
Install the camshaft pulley.
60. Install the timing belt. For more information, refer to the Timing Belt chapter in this section.
61. Fill the cooling system with coolant and bleed the system. Refer to Section 303-03 for additional information.
62. Add power steering fluid and bleed the system. Refer to Section 211-00 for additional information.
63. Install the battery tray and connect the battery. For more information, refer to Section 414-01.
64. Replace engine oil and oil filter.
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