Power unit, removal, Z19DT/DTH
Power unit, removal, Z19DT/DTH |
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To remove |
1. |
Place the car on a lift and apply wing covers.
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2. |
Open the cap on the expansion tank.
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3. |
Remove the upper engine cover, insulation and battery cover.
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4. |
Remove the battery cable.
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5. |
Remove the battery.
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6. |
Remove the glow plug control module and fuse holder from the battery tray.
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7. |
Unplug the bonnet switch connector and remove the battery tray.
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8. |
Raise the car slightly and remove the front wheels.
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9. |
Raise the car and remove the lower engine cover as well as the front spoiler shield. Unplug and remove the connector.
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10. |
Remove the right wing liner and detach the front part of the left wing liner so that the subframe is free.
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11. |
Undo the gearbox drain plug and drain off the gearbox oil.
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12. |
Fit the drain plug.
Tightening torque 50 Nm (37 lbf ft) |
13. |
Detach the headlight washer hose and plug the washer fluid reservoir.
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14. |
Lower the car slightly and remove the bumper.
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15. |
Remove the cover on the left-hand side.
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16. |
Remove the cover on the right-hand side and remove the connectors and clips from the engine control module.
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17. |
Remove the bracket from the body and the engine wiring harness.
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18. |
Lower the car.
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19. |
Remove the turbocharger intake hose.
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20. |
Remove the mass air flow sensor connector, air cleaner casing cover and air filter.
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21. |
Detach the intake hose and remove the air cleaner casing.
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22. |
Detach the fuel return hose. Plug both the hose and the pipe.
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23. |
Detach the fuel inlet hose. Plug both the hose and the pipe.
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24. |
Remove the fixings from the right structural member (front and rear). Carefully lift up the engine control module's wiring harness.
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25. |
Remove the turbo delivery pipe and hose from the turbocharger outlet.
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27. |
Detach the lower radiator hose from the engine.
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28. |
Disconnect the hose with quick coupling from the vacuum pump.
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29. |
Remove the turbocharger delivery hose from the throttle body and the turbo delivery pipe
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30. |
Remove the upper radiator hose.
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31. |
Detach the bleeder hose from the radiator.
Aut:
Detach the oil pipes from the radiator using
87 92 806 Removal tool, oil pipe, automatic transmission
.
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32. |
Remove the windscreen washer filler pipe.
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33. |
Remove the cover on the main fuse box and undo the two retaining screws.
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34. |
Disconnect the positive cable from the battery.
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35. |
Undo the screw securing the engine wiring harness connector in the electrical centre.
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36. |
Remove the engine harness clamp from the body and the ground cables.
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37. |
Detach the connector from the left structural member.
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38. |
Remove the radiator fan connector.
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39. |
Unplug the connector from the turbocharger solenoid valve.
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40. |
Detach the vacuum hoses from the turbocharger solenoid valve.
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41. |
Detach the wiring harness from the fan cowling.
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42. |
Unplug the connector from the particle filter pressure sensor and the rear temperature sensor.
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43. |
Fold up the engine wiring harness onto the engine.
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44. |
Unplug the coolant level sensor connector.
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45. |
Detach the vent hose from the engine.
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46. |
Detach the expansion tank from the body and remove the tank together with the hose.
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47. |
Remove the gear cables from the gearbox. Carefully bend the cables aside and secure them to the expansion tank bracket on the body using a cable tie.
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48. |
Fit
30 07 739 Hose pinch-off pliers
to the clutch hose and disconnect the quick-release coupling from the clutch slave cylinder.
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49. |
Undo the quick coupling on the right-hand coolant hose and the clips on the bulkhead. Catch any spilt coolant. Bend aside the hose and attach it to the engine.
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50. |
Option:
Detach the coolant hose that runs to the parking heater on the thermostat housing.
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51. |
Check and adjust the steering wheel and the steering assembly so that they are pointing straight ahead.
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52. |
Raise the car.
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53. |
Detach the steering shaft from the steering gear.
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54. |
Remove the multigroove belt. Mark the direction of belt rotation.
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55. |
Unplug the A/C compressor connector and remove the A/C compressor retaining bolts.
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56. |
Undo the drive shaft centre nuts. Knock loose the drive shafts from the hubs. Use
89 96 951 Puller, drive shaft
or a brass drift with mallet.
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57. |
Undo the nuts and the outboard steering links from the steering swivel member with
87 91 287 Puller, 150 mm
.
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58. |
Disconnect the lower links of the anti-roll bar. Use a thin wrench in the keys to hold them still.
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59. |
Option:
Remove the connector for the headlamp angle sensor and undo the cable from the subframe. Remove the bracket from the suspension arm.
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60. |
Undo the lower swivel joints from the steering swivel members and lower the suspension arms.
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61. |
Remove the right-hand drive shaft from the intermediate shaft.
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62. |
Remove the intermediate shaft.
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63. |
Remove the intermediate shaft bracket.
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64. |
Remove the front exhaust pipe.
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65. |
Fit
KM 6313 Centring fixture, subframe - engine
on the subframe. The bracket is installed in the A/C compressor's retaining bracket. Due to narrow tolerances on the drive shafts, the centring tool must be used to carefully fit the powertrain in against the subframe and body when reinstalled.
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66. |
Lower the car.
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67. |
Fit 2 x
83 95 212 Straps
to the radiator member. Lower one strap down around the radiator assembly. Wind an extra time around the A/C compressor to take the strain.
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68. |
Remove the right-hand engine pad.
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69. |
Remove the left engine pad.
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70. |
Raise the car.
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71. |
Position
83 96 137 Centring tool, subframe - body
on the trolley lift. Make sure the height adjusting screws 83 95 170 are in their lowermost position.
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72. |
Raise the trolley lift slightly so that it is firmly pressed against the subframe. Undo the bolts securing the subframe and subframe stay to the body.
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73. |
Carefully lower the power unit on the trolley lift, making sure nothing gets caught or damaged.
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