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Intake manifold/seal, Z19DTH

Intake manifold/seal, Z19DTH

Important

Always use wing covers when working in the engine bay.


To remove


1. Remove High-pressure pump .

2. Remove the EGR valve (606).

Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



3. Take the cap off the expansion tank to release any pressure.

4. Raise the car.

5. Undo the right-hand part of the front lower cover and bend down.

6. Place a receptacle under the radiator, connect a hose to the radiator and drain the coolant. Close the cock and fit the cover.


7. Lower the car.

8. Remove the turbocharger delivery hose from the pipe and throttle body.


9. Undo the coolant pipe to the reservoir from the engine.


10. Remove the coolant level sensor connector and bend away the reservoir.

11. Place a receptacle under the engine to collect the coolant. Remove the coolant hose from the coolant pipe.


12. Remove the coolant hose from the thermostat housing.


13. Undo the fixings and press down the wiring harness a little way.


14. Remove the nuts holding the coolant pipe to the starter motor bracket. Bend away the pipe slightly to give room for the vacuum reservoir.

15. Detach the vacuum hoses from the vacuum reservoir. Remove the vacuum pipe bolts from the camshaft housing and the oil trap bracket.


16. Remove the vacuum container.


17. Undo the oil trap upper hoses. The right-hand hose has a quick coupling to the oil trap.

18. Remove the nuts and bolts holding the oil trap bracket and bend it aside.

19. Undo the coolant line from the intake manifold.

Important

Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to Connectors, handling and inspection .



20. Remove the following connectors:

20.a. Throttle body actuator unit (604)


20.b. Coolant temperature sensor (202)

20.c. Glow plug connector (398).

20.d. Intake air sensor (688)

20.e. Fuel pressure sensor (653)

20.f. Fuel pressure control valve (652a)

21. Remove the stud holding the high-pressure pump.


22. Remove the connector to the combustion circulation actuator.

23. Remove the intake manifold.



To fit


1. Fit the intake manifold with new seal.

Tightening torque 27 Nm (20 lbf ft)


2. Connect the combustion circulation actuator.

3. Fit the stud.


4. Fit the coolant pipe to the intake manifold.

Important

Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to Connectors, handling and inspection .



5. Fit the wiring harness and plug in the following connectors:

5.a. Throttle body actuator unit (604)


5.b. Coolant temperature sensor (202)

5.c. Glow plug connector (398).

5.d. Intake air sensor (688)

5.e. Fuel pressure sensor (653)

5.f. Fuel pressure control valve (652a)

6. Bend the oil trap bracket back in place and fit the nuts and bolts.


7. Fit the oil trap upper hoses.

8. Fit the vacuum holder. Note that the narrow hose connection must be located at the top.

9. Fit the vacuum pipe on the camshaft housing and connect the hoses to the vacuum reservoir.


10. Fit the coolant pipes and wiring harness mountings to the starter motor bracket.


11. Fix the wiring harness to the brackets.

12. Fit the coolant hose to the coolant pipe.


13. Fit the coolant hose to the thermostat housing.


14. Fit the coolant pipe to the reservoir from the engine.


15. Fit the coolant reservoir and connector to the level sensor.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


16. Fit the turbocharger delivery pipe to the turbocharger delivery hose and the throttle body.


17. Fit the vacuum lines.

18. Fit High-pressure pump .

19. Fit the EGR valve.


20. Test pressurise, see Cooling system, pressure testing and top up with coolant, see Filling and bleeding the cooling system .

21. Connect an exhaust hose and start the engine. Check there are no leaks. Connect the diagnostic tool and clear any DTCs.