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Spare part engine block, Z19 DT, to remove

Spare part engine block, Z19 DT, to remove

To remove


1. Remove the power unit, see Power train removal.

2. Fit 32 025 020 Lifting eye if not already fitted.

3. Remove the electrical connections from the EHPS unit (A).


4. Remove the rear torque arm (A) from the subframe.


5. Remove the front torque arm (A) from the subframe.


6. Lift off the power unit from the subframe using 83 92 409 Lifting yoke .

7. Position the powertrain on a suitable work surface.

8. Remove the engine wiring harness:

- Remove the clips (A).


- Unplug the engine harness connector (B).

- Detach the electrical connections of the alternator (C).

- Detach the electrical connections of the starter motor (D).

- Detach the ground cable (E).

- Man : Unplug the connector of the reversing light switch (F).

- Aut : Unplug the TCM connector.

- Remove the wiring harness from the engine.

9. Detach the coolant lines:

- Detach the coolant lines at the oil cooler (A).


- Remove the bracket at the starter motor (B).

- Detach the coolant line at the EGR cooler (C).

- Detach the coolant line at the thermostat housing (D).

- Remove the bolt and the coolant line at the coolant pipe (E).


- Remove the bolt and the coolant line at the coolant pipe (F).

10. Remove the starter motor (A).


11. Remove the catalytic converter bracket (A).


12. Remove the gearbox (A).


13. Remove the engine wiring bracket:


- Open the clip and detach and unplug the connector (A).

- Remove the bolts (B) and move the wiring aside.

14. Remove the alternator (A).


15. Remove the belt tensioner (B) and the upper impeller (C).

16. Remove the A/C compressor bracket (A).


17. Remove the turbocharger intake manifold:

- Detach the hose at the camshaft cover (C).

- Remove the bolt (B).

- Detach the hose clip at the turbocharger and remove the intake manifold (C).

18. Remove the vacuum hose clips from the dipstick guide tube (F).

19. Remove the temperature sensor:


- Remove the temperature sensor (A).

- Unplug the connector (B)

- Remove the cable and bracket (C)

20. Remove the dipstick guide tube (D).

21. Remove the heat shield (E).

22. Remove the catalytic converter (A).


23. Detach the vacuum hoses from the solenoid valve (B).

24. Cars with vacuum tank: Detach the vacuum pipe:

- Remove the bolt on the camshaft cover (C).

- Remove the vacuum attachment on the vacuum pump (D).

25. Disconnect the wiring harness:


- Remove the wiring harness bracket (A).

- Open the clip and remove the cable (B).

- Remove the cable from the groove (C).

26. Remove the following connectors:


- EGR valve (A)

- Intake manifold temperature sensor (B)

- Fuel pump (C)

- Fuel rail (D)

- Oil pressure sensor (E)

- Crankshaft position sensor (F)

- Oil level sensor (G)

- Remove the clips (H)

27. Disconnect the wiring harness:


- Detach the fuel return line from the intake manifold bracket.

- Injectors (A)

- Intake manifold (B)

- Clip on the throttle body (C).

- Water temperature sensor on the thermostat housing (D)

- Throttle body (E)

- Fuel pressure sensor on the fuel rail (F)

- Disconnect the wiring harness

28. Remove the manifold:


- Detach the EGR connection (A).

- Detach the turbocharger's oil line on the engine block (B).

- Detach the turbocharger's oil return line from the engine block (C).

- Remove the nuts and the manifold (D).

29. Detach the fuel lines.


- Detach the return fuel lines from the injectors (A).

- Detach the return fuel line from the fuel pump.

- Remove the pressure regulator (C).

- Remove the return fuel line from the fuel rail (D).

30. Cars with vacuum tank: Detach the vacuum hoses' connection to the vacuum tank (A). Remove the bolts of the vacuum tank bracket (B).


31. Remove the EGR cooler:

- Remove the bolt on the cylinder head.

- Detach the connection to the EGR valve (D).

- Remove the nut on the thermostat housing (E).

- Detach the connection to the coolant pipe (F).

32. Remove the fuel rail:


- Remove the cable clip and move the cable aside (A).

- Detach the fuel pipe connections at the injectors (B).

- Detach the fuel pipe connection to the high-pressure pump (B).

- Detach the fuel pipe connections on the fuel rail (D).

- Remove the fuel rail (E).

33. Disconnect the glow plug (A) wiring harness.


34. Remove the crankshaft pulley (A).


35. Remove the timing cover (B)

36. Remove the lower timing cover (C).

37. Relieve tension in the belt tensioner and remove the timing belt (A).


38. Remove the high-pressure pump's bracket (A).


39. Remove the intake manifold:


- Remove the bleeder nipple of the thermostat housing (A).

- Remove the intake manifold (B)

40. Detach the crankcase ventilation hose (A).


41. Remove the thermostat housing (B).

42. Remove the vacuum pump (C).

43. Remove the camshaft sprocket (A) EN-46787 (1) and KM-956-1.


Important

Proceed with caution to ensure that the camshaft sensor is not damaged.


44. Remove the water pump (C).


- Remove the plastic guard (A) of the camshaft position sensor.

- Remove the Allen bolt of the camshaft position sensor (B).

- Remove the water pump (C) with camshaft position sensor (B).

45. Remove the belt tensioner (A) and impeller (B) of the timing belt.


46. Remove the intermediate plate (C).

47. Remove the coolant pipe (A).


48. Remove the oil filter housing (A).


49. Remove the crankshaft position sensor (B).

50. Remove the oil level sensor (C).

51. Remove the injectors (D).

52. Remove the glow plug (E).

53. Remove the pressure plate, clutch disc and flywheel.

54. Remove the cover (G).

55. Lift the engine from the work area and remove 32 025 020 Lifting eye if it was fitted.