Contents: Removal ⬇ Engine installation ⬇
Removal
Remove the gearbox from the engine.
Remove the oil dipstick guide tube.
Remove the bolt.
Remove the heated lambda fuel ratio sensor.
Disconnect the wiring harness connector.
Release the wiring harness.
Carefully unscrew the lambda sensor using the KM-6129 tool.
Remove the exhaust manifold shield.
Unscrew the 2 mounting bolts.
Remove the exhaust manifold.
Unscrew the 7 mounting nuts.
Remove the seal.
Raise the engine.
Install on the engine using the KM-412-18 fixture.
Tighten the 4 mounting bolts.
Mount the engine on the KM-412 2 fixture.
Tighten 8 threaded connections.
Install fixture KM-2358.
Drain the engine oil.
Place a receiving tray underneath.
Remove the drain plug.
Remove the oil filter housing cover.
Remove the oil filter insert.
Remove the clutch.
Remove the flywheel.
Install fixture KM-652.
Unscrew the 6 mounting bolts.
Remove the KM-652 fixture.
Remove the engine mount on the right 1.
Unscrew the 3 mounting bolts.
Tighten the oil drain plug.
Replace the sealing ring.
Tighten the bolt to a torque of 10 Nm.
Remove the oil pan.
Remove the poly V-belt.
Note: Mark the direction of rotation.
Tighten the poly V-belt tensioner in the direction of the arrow.
Insert the KM-955-2 tool.
Remove the poly V-belt from the crankshaft pulley.
Remove the coolant pump poly V-belt pulley.
Unscrew the 3 mounting bolts.
Remove the crankshaft poly V-belt pulley.
Unscrew the 6 mounting bolts.
Hold the crankshaft hub bolt.
Remove the poly V-belt tensioner.
Unscrew the 2 mounting bolts.
Remove the engine wiring harnesses.
Unscrew the generator wiring harness.
Unscrew 2 nuts.
Unbolt the starter wiring harness.
Unscrew 2 nuts 1.
Remove the cable ties.
Remove the generator.
Unscrew the 2 threaded connections.
Remove the starter.
Unscrew the 2 mounting bolts (arrows).
Remove the engine management system wiring harness.
On the Z 10 XEP engine: remove the fuel rail housing.
Unscrew the 2 mounting bolts.
Disconnect the 12 engine management system wiring harness connectors.
Oil pressure relay 6, coolant temperature sensor 8, camshaft sensor 9, throttle module 2, engine control module 12, EGR valve 4, ignition module 3, knock sensor 10, crankshaft sensor 11, fuel injectors 1.
Unscrew the ground wire of the engine control controller 13.
Clear the channel for the wire harness 7.
Release the wiring harness - 4 holders 14.
Disconnect 3 hoses from the coolant pump.
Disconnect the coolant hose from the EGR coolant flange.
Release the clamp.
Remove the coolant pump 1.
Note: Pay attention to the guide bushings when removing.
Place a receiving tray underneath.
Unscrew the 9 mounting bolts.
Note: Please note the different lengths of the mounting bolts (arrows – short bolts).
Remove the ignition module.
Remove the ignition module cover by sliding it to the right.
Unscrew the 2 mounting bolts.
Remove the cover using the KM-6009 1 tool.
Remove the cylinder head cover.
Remove the engine crankcase ventilation hose.
Release the clamp.
Remove 17 mounting bolts.
Loosen crankshaft hub bolt 1.
Note: This job requires two people.
Install and hold the KM-956-1 / KM-956-2 fixtures.
Hold KM-956-1 / KM-956-2.
Adjust the camshafts.
Using the KM-956-1 / KM-956-2 tool, turn the crankshaft evenly in the direction of engine rotation until the KM-953 1 tool fits into the camshaft groove as far as it will go.
Remove the crankshaft hub.
Note: Observe the mounting position of the hub.
Remove the bolt.
Remove the hub using tools KM-956-1 / KM-956-2.
Remove the oil pan.
Turn the engine 180°.
Unscrew the 14 mounting bolts.
Remove the oil pan seal.
Remove the timing belt housing.
Turn the engine 90°.
Remove 15 mounting bolts (arrows).
Take into account the length of the mounting bolts.
Do not damage the camshaft sensor 1.
Pry up and remove the timing belt housing sealing ring.
Note: Do not damage the sealing surface.
Remove the chain drive.
Loosen the camshaft drive gear bolts.
Hold the camshafts by the hex key.
Lock the chain tensioner 1.
Insert the KM-955-1 tool.
Remove the damper bar 3, guide bar 5, tensioner slides 7 and camshaft drive gears.
Remove camshaft drive chain 4 with drive wheel 6. Remove timing case seal.
Remove the cylinder head.
Turn the engine 90°.
Remove the KM-953 fixture.
Unscrew the 10 mounting bolts.
Note: Loosen the cylinder head studs in the order shown:
Note: - Loosen the cylinder head studs (90°);
Note: - Loosen the cylinder head studs (180°);
Note: – Remove the cylinder head studs.
Place the cylinder head into wooden blocks.
Remove the cylinder head gasket.
Remove the oil filter housing.
Unscrew the 3 mounting bolts.
Remove the knock sensor.
Remove the bolt.
Remove the oil deflector.
Rotate the engine 180°.
Unscrew the 6 mounting bolts.
Remove the crankshaft position sensor.
Remove the bolt.
Remove the cylinder block.
Install fixture KM-2358.
Suspend the engine from a crane.
Remove the KM-412-18 tool.
Install the cylinder block.
Install the KM-412-18 tool on the engine. Tighten the 4 mounting bolts.
Remove the KM-2358 fixture.
Press 6 guide sleeves into the cylinder block using the KM-427 tool.
Remove the suction oil line 1.
Unscrew the 4 mounting bolts.
Remove sealing ring 2.
Clean the sealing surfaces of the cylinder block and cylinder head, cylinder head cover, oil filter housing, crankshaft support, timing case, oil pan, coolant pump and exhaust manifold.
Engine installation
Inspect the powertrain components.
Note: If it is necessary to check and treat the cylinder head, remove all externally mounted parts from the cylinder head: cylinder block, cylinder head, cylinder head cover, oil filter housing, crankshaft support, chain drive, timing case, oil pan, coolant pump, exhaust manifold.
Using a straightedge and feeler gauge, check the cylinder head for evenness.
Lock the crankshaft.
Remove the screw plug 1.
Insert the KM-952 2 device in its place.
Turn the crankshaft evenly until the device is engaged.
Install the oil deflector.
Tighten the 6 mounting bolts to 8 Nm.
Install the oil filter housing.
Rotate the engine 180°.
Replace the seal.
Tighten the 3 mounting bolts to a torque of 20 Nm.
Replace the oil filter insert.
Install the oil filter housing cover.
Replace the sealing ring.
Tighten the cover mounting bolts to 10 Nm.
Adjust the camshafts.
Insert the KM-953 tool.
Turn the camshafts by the hexagon.
Remove the KM-953 tool.
Install the cylinder head.
Replace the seal.
Note: The "OPEN/TOP" marking must point upward.
Note: Replace the cylinder head bolts.
Using a straight edge, align the cylinder head with the cylinder block.
Tighten the 10 mounting bolts to a torque of 25 Nm. + 60° + 60°+60°.
Note: Observe the tightening sequence of the bolts.
Install the camshaft timing chain.
Install fixture KM-953.
Replace the timing case seal.
Note: Make sure the fit is correct (arrows).
Replace the bolts.
Move drive wheel 5.
Install the exhaust camshaft gear. Screw in the bolt.
Install the camshaft timing chain 3.
Insert the intake camshaft gear with the phase sensor disk into the camshaft drive chain and screw in the bolt.
Note: The phase sensor disk must be rotated manually.
Install the camshaft timing chain tensioner slide 6.
Tighten the bolt to a torque of 20 Nm.
Note: Make sure the camshaft drive chain is seated correctly.
Install the camshaft timing chain guide groove 4.
Tighten the 2 mounting bolts to 8 Nm.
Note: Make sure the camshaft drive chain is seated correctly.
Install the camshaft timing chain guide bar 2.
Tighten the 2 mounting bolts to 8 Nm.
Loosen the chain tensioner.
Remove the KM-9551 tool.
When replacing parts, consider the different design options. Make sure the part numbers are correct.
Install the coolant pump.
Note: Make sure the guide bushings (arrows) are seated correctly.
Replace seal 1.
Secure the pump using short mounting bolts 2.
Tighten the 3 mounting bolts to 8 Nm.
Remove the coolant pipe and unscrew the 3 mounting bolts.
Install the timing belt housing.
Screw in the bolts.
Note: Follow the tightening sequence
Tighten the 5 mounting bolts (M6) to 18 Nm.
Tighten the 14 mounting bolts (M6) to 28 Nm.
Tighten the 2 mounting bolts (M10) 3 to 35 Nm.
Install the coolant hose.
Check and clean the sealing surfaces.
Replace the sealing ring.
Tighten the 3 mounting bolts to 8 Nm.
Replace the crankshaft seal ring front 1.
Lubricate the sealing edges with silicone grease (white).
Install the KM-960 2 tool and press in the crankshaft seal ring.
Remove the KM-952, KM-953 tools.
Note: Fixation tools cannot be used for holding.
Install the crankshaft hub.
Observe the installation position of crankshaft hub 2, the mark must point upwards.
Replace the hub bolt.
Hold the hub using tools KM-956-1/ KM-956-2.
Tighten the bolt to 150 Nm. +45°.
Remove fixtures KM-956-1/ KM-956-2.
Install the crankshaft poly V-belt pulley 1.
Tighten the 6 mounting bolts to 8 Nm.
Hold the crankshaft hub bolt.
Insert the KM-952 tool.
Insert the KM-953 tool into the camshaft groove.
Install fixture KM-954 1.
Rotate the phase sensor disc 2 until it becomes possible to install the KM-954 device on the timing case.
Secure the camshaft drive gears.
Note: Tighten the camshaft drive gears and the phase sensor disc to 10 Nm.
Tighten the 2 mounting bolts to 210 Nm.
Note: Tighten the intake camshaft drive gear bolt first.
Support the camshafts using hexagon 1.
Remove the fixing tools KM-952, KM-953, KM-954.
Tighten the camshaft drive gears.
Tighten the 2 mounting bolts to a torque of 50 Nm + 60°.
Note: Tighten the intake camshaft drive gear bolt first.
Note: Hold the camshafts by the hex key.
Check the valve timing.
Install the oil pan.
Tighten the 14 mounting bolts to 10 Nm.
Install the crankshaft support plug.
Replace the sealing ring.
Tighten the mounting bolt to a torque of 50 Nm.
Install the knock sensor.
Tighten the mounting bolt to a torque of 20 Nm.
Install the crankshaft position sensor.
Replace the sealing ring.
Tighten the mounting bolt to 8 Nm.
Install the cylinder head cover 1.
Rotate the engine 180°.
Replace seal 2, O-ring.
Apply sealant (distance 1–2 mm).
Note: Complete installation work within 10 minutes.
Tighten the 17 mounting bolts to 8 Nm.
Install the engine crankcase ventilation hose.
Secure the clamp.
Install the ignition module.
Tighten the 2 mounting bolts to 8 Nm.
Install the coolant hoses.
Secure the clamps to the coolant pump and EGR valve.
Install the engine management system wiring harness.
Route the wiring harness.
Connect the 13 wire harness connectors.
Connect the ground wire to the engine control module.
Tighten the mounting nut.
Secure the wiring harness channel.
Secure the wiring harness.
On the Z 10 XEP engine: Install the fuel rail housing.
Tighten the 2 mounting bolts.
Install the starter.
Rotate the engine 90°.
Tighten the 2 mounting bolts to 25 Nm.
Install the generator.
Tighten the 2 threaded connections to a torque of 35 Nm.
Install the engine wiring harness.
Rotate the engine 90°.
Secure the generator and starter wire harnesses and tighten the 4 mounting nuts.
Install the poly V-belt tensioner.
Rotate the engine 180°.
Tighten the bolt (M8) to a tightening torque of 20 Nm.
Tighten the bolt (M10) to a tightening torque of 55 Nm.
Install the coolant pump poly V-belt pulley.
Tighten the 6 mounting bolts to a torque of 20 Nm.
Install the poly V-belt.
Note: Observe the direction of rotation and installation position.
Loosen the tension of the poly V-belt tensioner.
Remove the KM-955-2 tool.
Install the motor holder on the right.
Tighten the 2 mounting bolts to 60 Nm.
Install the flywheel.
Clean the 6 threaded connections in the crankshaft.
Replace the mounting bolts.
Tighten the 6 mounting bolts to 35 Nm. +60°.
Lock the flywheel using the KM-652 tool.
Install the clutch.
Fill with engine oil.
Check and, if necessary, adjust the engine oil level.
Disconnect the engine from the KM-412 fixture.
Unscrew 8 threaded connections.
Remove the KM-412-18 tool.
Unscrew the 4 mounting bolts.
Install the exhaust manifold.
Replace the seal.
Replace the nuts.
Tighten the 7 mounting nuts to a tightening torque of 20 Nm.
Install the exhaust manifold shield.
Tighten the 2 mounting bolts to 8 Nm.
Install a heated lambda sensor to control the fuel mixture composition.
Apply mounting paste (white) to the threads.
Tighten the lambda sensor to 40 Nm.
Connect the wire harness connector.
Secure the wiring harness.
Install the oil dipstick guide tube.
Replace 2 O-rings.
Tighten the bolt to 8 Nm.
Install the gearbox on the engine.
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