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Power unit, removal, Z19DT/DTH

Power unit, removal, Z19DT/DTH

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


To remove


1. Place the car on a lift and apply wing covers.

2. Open the cap on the expansion tank.


3. Remove the upper engine cover, insulation and battery cover.

4. Remove the battery cable.

5. Remove the battery.

6. Remove the glow plug control module and fuse holder from the battery tray.


7. Unplug the bonnet switch connector and remove the battery tray.

8. Raise the car slightly and remove the front wheels.

9. Raise the car and remove the lower engine cover as well as the front spoiler shield. Unplug and remove the connector.


10. Remove the right wing liner and detach the front part of the left wing liner so that the subframe is free.


11. Undo the gearbox drain plug and drain off the gearbox oil.


12. Fit the drain plug.

Tightening torque 50 Nm (37 lbf ft)

13. Detach the headlight washer hose and plug the washer fluid reservoir.


14. Lower the car slightly and remove the bumper.


15. Remove the cover on the left-hand side.


16. Remove the cover on the right-hand side and remove the connectors and clips from the engine control module.


17. Remove the bracket from the body and the engine wiring harness.


18. Lower the car.

19. Remove the turbocharger intake hose.


20. Remove the mass air flow sensor connector, air cleaner casing cover and air filter.

21. Detach the intake hose and remove the air cleaner casing.

Important

Be very thorough in terms of cleanliness when working in the fuel system. Malfunctions can also occur due to very small dirt particles. Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal. Store the components so that contaminants cannot enter.


Warning

The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


22. Detach the fuel return hose. Plug both the hose and the pipe.


23. Detach the fuel inlet hose. Plug both the hose and the pipe.

24. Remove the fixings from the right structural member (front and rear). Carefully lift up the engine control module's wiring harness.


25. Remove the turbo delivery pipe and hose from the turbocharger outlet.


26. Remove the turbocharger intake pipe and plug it. Undo the crankcase ventilation hose.


Note

Take extra care in cars with preheated crankcase ventilation to ensure that the heating coil in the hose is not damaged.


27. Detach the lower radiator hose from the engine.

28. Disconnect the hose with quick coupling from the vacuum pump.


29. Remove the turbocharger delivery hose from the throttle body and the turbo delivery pipe

30. Remove the upper radiator hose.

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 .


32. Remove the windscreen washer filler pipe.

33. Remove the cover on the main fuse box and undo the two retaining screws.

34. Disconnect the positive cable from the battery.

35. Undo the screw securing the engine wiring harness connector in the electrical centre.

36. Remove the engine harness clamp from the body and the ground cables.

37. Detach the connector from the left structural member.

38. Remove the radiator fan connector.


39. Unplug the connector from the turbocharger solenoid valve.

40. Detach the vacuum hoses from the turbocharger solenoid valve.

Note

"VAC" is connected to the vacuum pump and "OUT" is connected to the turbocharger.


41. Detach the wiring harness from the fan cowling.

42. Unplug the connector from the particle filter pressure sensor and the rear temperature sensor.


43. Fold up the engine wiring harness onto the engine.

44. Unplug the coolant level sensor connector.


45. Detach the vent hose from the engine.

46. Detach the expansion tank from the body and remove the tank together with the hose.

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.


48. Fit 30 07 739 Hose pinch-off pliers to the clutch hose and disconnect the quick-release coupling from the clutch slave cylinder.

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.


50. Option: Detach the coolant hose that runs to the parking heater on the thermostat housing.

51. Check and adjust the steering wheel and the steering assembly so that they are pointing straight ahead.

Warning

In order to avoid the contact roller for the airbag twisting and breaking the steering wheel must be secured via the steering column lock or by taping it to the panel.


52. Raise the car.

53. Detach the steering shaft from the steering gear.


54. Remove the multigroove belt. Mark the direction of belt rotation.


55. Unplug the A/C compressor connector and remove the A/C compressor retaining bolts.


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.

57. Undo the nuts and the outboard steering links from the steering swivel member with 87 91 287 Puller, 150 mm .


58. Disconnect the lower links of the anti-roll bar. Use a thin wrench in the keys to hold them still.

59. Option: Remove the connector for the headlamp angle sensor and undo the cable from the subframe. Remove the bracket from the suspension arm.

60. Undo the lower swivel joints from the steering swivel members and lower the suspension arms.

61. Remove the right-hand drive shaft from the intermediate shaft.


62. Remove the intermediate shaft.


63. Remove the intermediate shaft bracket.

64. Remove the front exhaust pipe.


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.


66. Lower the car.

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.


68. Remove the right-hand engine pad.


69. Remove the left engine pad.

70. Raise the car.

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.

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.


73. Carefully lower the power unit on the trolley lift, making sure nothing gets caught or damaged.