Immobilise Engine at TDC on Cylinder No. 1 (Check Valve Timing)
Disconnect negative lead from battery - see operation "Battery Negative Lead, Disconnect and Connect" in Group "N".
Remove the windscreen washer reservoir - see operation "Windscreen Wash/Wipe Reservoir, Remove and Install" in Group "N".
Disconnect ground cable (2) from timing case.
Detach positive cable (1) from central electrics housing.
Disconnect central connector (3) (black) from central electrics housing.
Lay central electrics housing and wiring harnesses to one side (make battery accessible).
Remove battery and battery tray.
Detach wiring harness plug (3) from hot film mass air flow sensor.
Detach air intake hose and air intake pipe (1) from turbocharger, cylinder head cover and air cleaner housing.
Lay solenoid valve bracket (4) to one side.
Detach intercooler pipe with intercooler hose (2) from turbocharger, cylinder head cover and intercooler.
Detach vacuum line duct (5) from cylinder head cover and lay towards the front.
Detach wiring duct (7) from cylinder head cover/intake manifold upper part and lay towards the front.
Unclip glow plug wiring harness (6) from cylinder head cover.
Detach cylinder head cover (8) from cylinder head.
Detach brake servo vacuum line (2) and vacuum hose (3) from vacuum pump.
Detach retaining bolts (1) from both engine transport brackets and lay bracket with wiring harness down out of the way.
Remove retaining bolts (4) and remove vacuum pump from cylinder head.
Remove lower right�hand wheel housing trim panel.
Mark rotational direction of ribbed V�belt. Tension ribbed V�belt tensioner by turning cast hex (1) in direction of arrow (anti�clockwise), and remove ribbed V�belt.
Remove retaining bolts (2) and (3) - remove ribbed V�belt tensioner.
Remove retaining bolts for timing case cover (1) and carefully separate timing case cover from timing case using a wide, flat scraper (2).
The timing case cover must not be levered off or removed with force from the timing case, as any permanent deforming would cause leaks.
Turn the crankshaft by the vibration damper bolt until just before TDC on cylinder no. 1. - marking (3) on the vibration damper should be just before cast lug (2) on the timing case.
In this position both cams (1) for cylinder no. 1 are just before TDC (both cams point upwards).
Remove crankshaft position sensor (1) with O�ring from cylinder block.
Insert crankshaft timing peg KM�929 (2) into the opening for the crankshaft position sensor, and at the same time slowly turn the crankshaft by the vibration damper bolt in the normal direction of rotation until the crankshaft timing peg can be fully inserted into the cylinder block/crankshaft web.
In this position markings (3) must line up.
Arrow (1) on simplex injection pump sprocket must line up with cut�out in injection pump flange and timing hole (2) in injection pump.
Insert injection pump timing peg KM�927 (3) into injection pump timing hole.
Position test gauge KM�932 (3) on cylinder head - peg (2) must locate in hole (1) on the camshaft.
Remove all timing tools.
Clean the sealing faces of the timing case cover and the timing case - cover the opening in the timing case with a lint�free cloth.
Assemble the timing case cover and check the torque within 10 minutes of applying the silicone sealer (grey).
Apply an approx. 2 mm (measurement I) thick bead of silicone sealer to the timing case cover. Attach the timing case cover to the timing case - use two M6 studs to locate - torque 6 Nm.
Attach the ribbed V�belt tensioner to the auxiliary mounting bracket - torque 42 Nm. Attach the vibration damper (ribbed V�belt tensioner) to the auxiliary mounting bracket - torque 20 Nm. Lay ribbed V�belt in place and tension via the ribbed V�belt tensioner. Note rotation direction and installation position of ribbed V�belt.
Attach crankshaft position sensor to cylinder block using new O�ring - torque 8 Nm.
Attach vacuum pump (1) with new oil seal (2) to cylinder head - torque 8 Nm.
Attach vacuum hose and brake servo vacuum line to vacuum pump.
Attach wiring harness brackets to both engine lifting brackets.
Attach new gasket (4) to cylinder head cover. Gasket must be inserted into gap (3) between cylinder head cover and sleeve.
Apply sealing compound (black) to the sealing surfaces (arrows).
Attach cylinder head cover to cylinder head - torque 8 Nm.
Clip glow plug wiring harness onto cylinder head cover.
Attach wiring duct to cylinder head cover and intake manifold upper part.
Attach vacuum line duct to cylinder head cover.
Attach intercooler pipe and intercooler hose to turbocharger, cylinder head cover and intercooler using a new seal.
Slide the solenoid valve bracket onto the mounting.
Attach air intake hose and air intake pipe to air cleaner housing, cylinder head cover and turbocharger - check for proper fit.
Connect wiring harness plug to hot film mass air flow sensor.
Install battery and battery tray.
Connect central connector (black) and positive cable to central electrics housing.
Connect ground cable to timing case.
Install windscreen washer reservoir - see operation "Windscreen Wash/Wipe Reservoir, Remove and Install" in Group "N".
Connect negative lead to battery - see operation "Battery Negative Lead, Disconnect and Connect" in Group "N".