V70 D5244T 2002
V70 D5244T 2002
V70 D5244T 2002
28/12/2010 PRINT
21: Cylinder head, D5244T
Cylinder
head/gasket,
replacing
Special tools:
999 5199
951 2050
951 2767
999 7005
999 7006
999 7007
999 7010
999 7015
Removing the
cylinder head
Note! The
illustrations in this
service
information are
used for different
model years
and/or models.
Some variation
may occur.
However, the
essential
information in the
illustrations is
always correct.
Safety
Caution! FIRE
RISK. Take great
care to avoid
causing sparks and
fuel leakage when
working on the
fuel system.
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Preparation
Remove:
the radiator breather tube
from the expansion tank.
Install lock grip pliers
the expansion tank cap
the right front wheel
the plastic nuts on the cover
at the right wing liner.
Draining coolant
Separating the
exhaust system
Remove:
the nuts at the junction of the
turbocharger and front
exhaust pipe. Use rust-
proofing agent
the screw for the front
exhaust pipe and support
bracket.
Remove:
the oil
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drainage pipe
the grommet
from the block
the clamp
holding the oil
pressure pipe
to the coolant
pipe
the vacuum
hose to the
variable nozzle
turbo
governor.
Remove:
the tie strap
for the servo
hose from the
engine
stabiliser brace
the cross stay
between the
suspension
turrets
the engine
cover by
pulling it
straight up
the pipe
screws for the
turbocharger
(TC) oil
pressure pipe
the screw for
the charge air
pipe in the
vacuum pump.
Slacken off the
hose clamp for
the intake hose
for the
turbocharger
(TC). Push the
hose to one
side
the screws for
the exhaust
gas
recirculation
(EGR) pipe
connection to
the exhaust
gas
recirculation
(EGR) valve
the nuts for
the exhaust
manifold. Use
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rust-proofing
agent
the exhaust
manifold and
turbocharger
(TC). Slowly
lower the unit
onto the drive
shaft and
steering gear
the screw that
holds the
coolant pump
inlet pipe onto
the cylinder
block.
Position the
engine according
to the marking
Remove:
the timing belt
cover
the servo
reservoir. Lift
up and place
on top of the
engine.
Warning! Ensure
that no power
steering fluid is
spilled.
Disconnecting the
belt tensioner
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Removing the
timing gear pulley
Remove:
the screws. Use counterhold
999 5199 .
the timing gear pulley
the two screws for the inner
timing belt cover
the idler pulley.
Remove:
the fresh air intake for the
air cleaner (ACL) housing
the solenoid valve
the clips for the cable
harness from the air cleaner
(ACL) housing
the connector from the mass
air flow (MAF) sensor.
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housing assembly.
Remove:
the connector and positive
power supply in the central
electrical unit
the two screws for the
central electrical unit and lift
to one side.
Removing
components
Remove:
the coolant hose from the
thermostat housing
the support for the power
steering pump against the
cylinder head
the rear / upper engine
mounting bracket
the intake hose between the
exhaust gas recirculation
(EGR) mixer and intake
the crankcase ventilation pipe
hose from the flame trap
the two screws from the
bracket for the crankcase
ventilation pipe
the connector from the
solenoid valve on the air filter
housing
the charge air pipe assembly
with the crankcase ventilation
hose.
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Remove:
the delivery line. Plug the
pipes
the suction and return hose
the three mounting screws
for the injection pump
the fuel injection pump.
Remove:
both the vacuum pump
hoses
the vacuum pump screws
the vacuum pump.
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recirculation (EGR)
cooler onto the
gearbox.
Remove:
the return hose from the
engine return pipe
the delivery line
the fuel rail
the injectors. Counterhold the
delivery line terminal in the
nozzle (1) when removing
the screws for the mountings
for the fuel rail on the
cylinder head.
Remove:
the intake /
camshaft cover
rear oil seal
cap / pump
bracket.
Removing the
camshafts and
bearing cap
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Removing the
cylinder head
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example) surface.
This is to prevent
damage to the
gasket surface of
the cylinder head.
Replacing the
cylinder head
Remove:
the thermostat
housing
the glow plugs.
Caution! To
prevent
damage to
the glow
plugs, they
must be
tightened to
the correct
torque. See
Tightening
torque .
Caution! Do not
damage the
mating surfaces.
Cleaning the
gasket faces
Clean the
gasket faces
for:
the manifold
Check that the
stud threads
are
undamaged
and are
tightened
the coolant
bypass channel
the thermostat
housing
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the cylinder
block
camshaft
cover.
Caution! Use a
razor blade or a
gasket scraper and
gasket solvent
1161 440.
Warning! Use a
fume hood or
extractor when
using gasket
solvent!
Installing the
cylinder head
Caution! For
tightening torques
not in the text, see
Tightening torque .
Aligning the
crankshaft
Remove:
starter motor
the blind cover plug.
Install:
thermostat
housing. Use a
new gasket
the glow plugs.
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Caution! Handle
the cylinder head
carefully so that
the gasket faces
are not damaged.
Selecting the
correct thickness
for the cylinder
head gasket
Installing the
cylinder head
1. 20 Nm
2. Remove
3. 20 Nm
4. 50 Nm
5. 90 degrees.
Use protractor
951 2050 .
6. 90 degrees
Installing tappets
and rocker arms
Lubricate the
tappets. Install the
tappets in the
marked order.
Check that the
tappets are correctly
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positioned against
the valve stems.
Installing
camshafts and
camshaft covers
Lubricate:
the camshaft bearing
positions and lobes
the cylinder head bearing
positions
the camshaft cover
the rollers for the rocker
arms.
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Warning! Use a
fume bonnet or
extractor when
using gasket
solvent.
Caution! Use a
razor blade or a
gasket scraper and
gasket solvent
1161 440.
Installing the
valve cover
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necessary. Use
engine oil.
Installing toothed
belt
Install:
the 2 screws for the inner
timing belt cover
the idler pulley. Tighten to
25Nm
the timing gear pulley, using
three screws until they just
affect the pulleys
the timing belt.
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to 30 Nm. Use
counterhold 999
5199
Remove:
camshaft adjustment tool
using tool 999 7007
crankshaft adjustment tool
using tool 999 7005 .
Check
Install:
the timing belt cover
the auxiliaries belt
the expansion tank and the
bleed hose to the expansion
tank
the servo reservoir.
Installing injectors
Note! For
tightening torques,
see Tightening
torque .
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Remove:
the snap ring (3). Use tool
999 7015
the shim (2)
the tensioned mounting
yokes (6).
Install:
a new tensioned mounting
yoke. Lock the shim using a
new snap ring. Use tool 999
7015
injectors with new seal
washers (4) and screws (7).
Use tool 999 7010 to guide
the injectors into the correct
position. Tighten the
injectors. Tighten to 10 Nm.
Start with cylinder 3. Then 2,
4, 1, 5.
Install:
the screws for
the mountings
for the fuel rail
on the cylinder
head.
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Caution! Do NOT
counterhold the
injector cap nuts
(5).
Installing the
exhaust gas
recirculation (EGR)
cooler
Install:
Exhaust gas
recirculation
(EGR) cooler.
Tighten
the hose from
the charge air
cooler (CAC)
on the mixer.
Installing the
vacuum pump
Install:
the vacuum pump. Use new
O-rings. Tighten to 17 Nm
both the hoses for the
vacuum pump.
Install:
the fuel injection pump.
Tighten to 17 Nm
new delivery line .
the suction pipe and return
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Installing the
cable harness
the injectors
exhaust gas recirculation
(EGR) actuator
the fuel control valve
the glow plugs
the fuel pressure sensor
the variable nozzle turbo
governor
the engine coolant
temperature sensor.
Installing
components
Install:
the rear / upper engine
mounting bracket
the return hose for the
injectors
the crankcase ventilation
hose on the valve cover
the charge air pipe assembly
with the crankcase ventilation
hose
the connector for the solenoid
valve
the screw for the bracket for
the crankcase ventilation pipe
the hose for the crankcase
ventilation pipe on the flame
trap
the intake hose between the
exhaust gas recirculation
(EGR) mixer and intake
the support for the power
steering pump against the
cylinder head
the engine coolant hose on
the thermostat housing
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Install:
the two screws for the
central electrical unit
the connector and positive
power supply in the central
electrical unit
air cleaner (ACL) housing
the hose for the mass air
flow (MAF) sensor on the
charge air pipe
the connector for the mass
air flow (MAF) sensor
the solenoid valve and cable
harness clip in the air cleaner
(ACL) housing
the fresh air intake for the
air cleaner (ACL) housing
Installing
components
Install:
the screw that holds the
coolant pump inlet pipe onto
the cylinder block.
the exhaust manifold and
turbocharger (TC) using a
new gasket. Use new nuts.
Tighten to 30 Nm
the screws for the exhaust
gas recirculation (EGR) pipe
connection to the exhaust gas
recirculation (EGR) valve
the inlet hose for the
turbocharger (TC). Tighten
the clamp
the front exhaust pipe in the
turbocharger (TC) using new
nuts and a new gasket
the upper pipe screw for the
turbocharger (TC) oil
pressure pipe. Do not tighten.
Use new seal washers.
Tighten the screw for the
charge air pipe in the vacuum
pump.
Installing
components
underneath the car
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Install:
the lower pipe
screw in the
block for the
oil pressure
pipe. Tighten
to 38 Nm
the clamp
holding the oil
pressure pipe
to the coolant
pipe
the vacuum
hose on the
variable nozzle
turbo governor
the oil
drainage pipe.
Use a new
grommet and
gasket
the charge air
hose for the
turbocharger
(TC). Tighten
the clamp
the screw for
the front
exhaust pipe
and support
bracket
the plastic nuts
on the cover at
the right wing
liner.
the right front
wheel. See
Installing
wheels .
the splash
guard under
the engine
the battery
negative lead.
Also read
Battery,
disconnecting .
Tighten the oil
pressure pipes
in the
turbocharger
(TC). Tighten
to 18 Nm
the engine
cover
the cross stay
between the
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suspension
turrets
the tie strap
for the servo
hose from the
engine
stabiliser brace
Check
Check:
the engine oil
level
the servo oil
level
the coolant
level.
Function test
Run the engine at
fast idle speed until
the thermostat
opens.
Ensure that the
heater control in the
passenger
compartment is at
the maximum
position.
Check the engine for
leaks.
Top up the coolant if
necessary.
28/12/2010 PRINT
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