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EGR cooler, Z19DTH

EGR cooler, Z19DTH

Important

Always use wing covers when working in the engine bay.


To remove


1. Remove the upper engine cover and insulation.


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


2. Drain the coolant, see Draining, cooling system .

3. Remove the lower engine cover.


4. Lower the car.

5. Remove the glow plug control module from the battery tray.


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


7. Detach the coolant hose from the thermostat and bend it down.


8. Undo the mountings for the pipe to the coolant reservoir

9. Remove the coolant hose from the pipe to the oil cooler.


10. Remove the rear coolant hose from the cooler.

11. Remove the cooler pipe connections from the EGR valve and exhaust manifold.


12. Undo the coolant pipe mountings from the intake manifold.


13. Remove the cooler bolts from the cylinder head.


14. Undo the thermostat housing and move it away.

15. Remove the front coolant hose from the cooler.

16. Remove the cooler complete with pipe.

17. Clean the engine bay from spilled coolant.


To fit


1. Put the cooler in place.


2. Fit the thermostat housing with a new seal greased with Vaseline.

Tightening torque 25 Nm (18 lbf ft)

3. Fit the coolant pipe to the intake manifold.


4. Fit the front coolant hose to the cooler.


5. Fit the cooler to the EGR valve and exhaust manifold with new seals. Do not tighten the bolts yet.

6. Fit the cooler to the cylinder head and tighten the bolts.

Tightening torque to cylinder head 25 Nm (18 lbf ft)

Tightening torque to EGR valve 20 Nm (15 lbf ft)

Tightening torque to exhaust manifold 20 Nm (15 lbf ft)


7. Fit the rear coolant hose to the cooler.

8. Fit the coolant hose to the oil cooler pipe.


9. Fit the pipe to the coolant reservoir.


10. Fit the upper coolant hose.

11. Fit the turbocharger delivery hose.

Tightening torque 3.5 Nm (2.5 lbf ft)


12. Fit the glow plug control module.


13. Fit the insulation and the upper engine cover.

14. Pressure test the cooling system, see Cooling system, pressure testing .

15. Fill with coolant, see Filling and bleeding the cooling system .

16. Raise the car.

17. Fit the lower engine cover.


18. Lower the car.