Spare part engine block, Z19 DTH, to remove
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Spare part engine block, Z19 DTH, to remove
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1.
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Remove the power unit, see Power train removal.
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3.
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Remove the electrical connections from the EHPS unit (A).
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4.
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Remove the rear torque arm (A) from the subframe.
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5.
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Remove the front torque arm (A) from the subframe.
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7.
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Remove the electrical connections from the alternator (A).
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8.
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Remove the electrical connections from the starter motor (A).
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9.
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Unplug the connector for the TCM (A) and undo the clips (B).
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10.
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Unplug the engine harness connector (A), remove the bracket (B) and clip (C).
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11.
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Remove the wiring harness from the engine.
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12.
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Remove the cable mounting (A) located on the coolant pipes/starter motor. Remove the starter motor (B).
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13.
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Raise the unit for better access.
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14.
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Remove the front catalytic converter bracket (A).
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15.
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Aut
: Undo the 6 bolts (A) holding the torque converter to the driver plate. Rotate the engine clockwise on the pulley centre bolt.
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16.
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Man
: Remove the gearbox bolts and lift it away from the engine.
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17.
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Aut
: Remove the gearbox bolts (A). Pull out the gearbox about 10 mm.
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18.
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Undo the plug and press the torque converter against the gearbox, fit
87 92 574 Holder
for holding the torque converter in place and remove the gearbox (A).
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19.
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Remove the pipe (A) to the coolant reservoir.
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20.
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Remove the coolant pipes (A) leading to the oil cooler.
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21.
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Remove the EGR cooler (A) assembly.
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23.
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Man
: Remove the bolts holding the pressure plate and remove the clutch.
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24.
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Man
: Remove the clutch plate.
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25.
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Remove the flywheel/driver plate (A).
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26.
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Remove the flywheel locking attachment (B).
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27.
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Remove the protective plate.
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29.
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Drain the engine oil and remove the oil filter cap and the filter.
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30.
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Undo the vacuum hose (A) from the diaphragm box.
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31.
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Remove the bracket for the temperature sensor's connector:
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Unplug the connector (B)
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Detach the cable from the clip
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Remove the connector's bracket (B)
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32.
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Remove the dipstick pipe (C).
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33.
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Remove the heat shield (D)
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34.
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Remove the turbocharger oil delivery line and return line from the engine block. (A)
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35.
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Remove the turbo from the catalytic converter (B).
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36.
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Remove the AC bracket (C).
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37.
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Remove the alternator (A).
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38.
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Remove the crankcase ventilation hoses from the engine, the oil sump and the oil filler connection pipe. Open the hose's clip. (A)
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39.
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Remove the oil trap hose with quick coupling (B).
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40.
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Undo the wiring harness from the bracket and unplug the combustion circulation connector.
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41.
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Open the wiring harness clip (A).
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42.
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Remove the bracket for the oil separator.
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43.
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Remove the thermostat housing:
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Remove the bolts (A)
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Remove the hose from the thermostat housing (B)
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Unplug the connector (C)
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44.
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Remove the crankshaft pulley (A).
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45.
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Remove the idler pulley centre bolt on the lower timing cover (B). Use, for example, 2 screwdrivers to carefully prize off from two directions.
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46.
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Remove the upper timing cover (C).
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47.
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Remove the lower timing cover (D).
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48.
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Undo the crankcase ventilation pipe and hose form the camshaft housing.
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49.
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Reset the engine by removing the plug and fitting
32 025 008 Camshaft fixing tool
(A). Turn the engine until the tool clicks and locks the exhaust camshaft.
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50.
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Relieve tension in the belt tensioner and remove the timing belt (B). Mark the direction of rotation if the timing belt is to be refitted.
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51.
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Remove the vacuum line from the cable jointing chamber.
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52.
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Remove the engine wiring harness by unplugging the following connectors:
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Pressure switch, engine oil (44) (A)
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Level sensor, engine oil (243) (B)
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Crankshaft position sensor (345) (C)
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EGR solenoid valve (606) (D)
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Fuel quantity control valve, high-pressure pump (652b) (E)
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Throttle body actuator unit (604) (F)
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Intake air sensor (688) (G)
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Camshaft position sensor (555) (H)
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Fuel pressure sensor (653) (J)
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Fuel pressure control valve (652a) (K) (certain cars)
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Glow plug connector (L)
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53.
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Remove the cable duct.
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54.
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Lift off the wiring harness.
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55.
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Remove the oil cooler:
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Detach the lower coolant connection to the oil cooler (A).
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Remove the oil cooler (B).
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56.
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Remove the coolant pipe on the intake manifold (A)
Important
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The return line must not be removed from the fuel return's damping housing. Otherwise it must be replaced.
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57.
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Remove the return line, injector:
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Remove the return line on the injectors (E)
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58.
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Remove the fuel rail:
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Remove the high-pressure hose, fuel rail - high-pressure pump (D)
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Remove the high-pressure hoses to the injectors (C)
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Remove the return hose (A)
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Remove the screws that hold the fuel rail (B)
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59.
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Remove the coolant pipe (A).
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60.
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Remove the timing belt cover's holder (B).
Important
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If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.
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61.
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Remove the injectors:
Note
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If the nozzles cannot be raised by hand, use 32 025 013 Injector removal tool with 83 90 270 Sliding hammer and 32 025 012 Sliding hammer adapter.
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Remove the injectors in the following order, 1-2-3-4. Illustration
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Remove the nut for the injector (A) holder.
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Lift up the injector (A) (small illustration)
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62.
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Remove the glow plug (B).
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63.
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Undo the nut on the high-pressure pump gear:
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Counterhold with tools KM-6347 and KM-956-1.
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64.
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Remove the high-pressure pump gear:
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Pull away the high-pressure pump's drive wheel (A)
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Counterhold with an open spanner
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65.
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Certain cars
: Remove the bracket (A).
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66.
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Remove the high-pressure pump:
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Remove the high-pressure pump's return hose (A)
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Remove the high-pressure pump (B)
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67.
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Remove the high-pressure pump's bracket (A).
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68.
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Remove the intake manifold with throttle valve module and EGR valve (A).
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69.
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Remove the noise absorbing panel on the oil sump (A).
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70.
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Remove the bracket to the exhaust pipe on the lower section of the rear edge of the oil sump (B).
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71.
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Remove the coolant pump (A).
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72.
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Remove the tension pulley (B).
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73.
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Remove the idler wheel (C).
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75.
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Remove the engine cover bracket (A).
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78.
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Detach the engine from the engine stand.
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79.
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Position the engine on a suitable surface.
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80.
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Detach the engine lift from the engine and remove the lifting eyes from the engine.
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