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Powertrain, installation, Z19DTR

Powertrain, installation, Z19DTR

Warning

A large number of hoses, cables, etc., are secured with cable ties. After tightening, the ties are cut off and leave more or less sharp edges at the fastening point. Watch out for the risk of cuts due to these sharp ends on the cable ties!


To fit


1. Position the trolley lift with power train and adjust its position in relation to the body. Use 82 93 102 Extension, 500 mm, 3/8 square through the holes in the subframe to the attachments in the body. See Centring tool, engine and subframe.

2. Lift up the powertrain until the left drive shaft universal joint is level with the wheel hub and insert the drive shaft into the hub. Make sure nothing gets caught or damaged.

3. Position the A/C compressor and insert the bolts.


4. Position the hose for automatic gearbox bleeding.

5. Make sure that the radiator core's locating pins engage in their mountings.

6. Lift a little higher and position the lower swivel joints to the steering swivel members. If necessary, adjust the trolley lift screws to provide even contact with the body. Check that the guide pins are positioned correctly relative the reference holes in the body.

7. Position the bolts and screw them through the subframe into the body.

8. Raise the engine fully and tighten the subframe bolts (A) and subframe stay bolts (B) to the body.

Tightening torque, subframe: 75 Nm + 135° (55 lbf ft +135°)

Tightening torque, stay: 90 Nm + 45° (66 lbf ft +45°)


9. Lower the trolley lift and move it out of the way.

10. Lower the car.

11. Fit the left engine mounting (B).

Tightening torque: 70 Nm +45° (52 lbf ft +45°)


12. Fit the right engine mounting (A).

Tightening torque: 70 Nm +60° (52 lbf ft +60°)

13. Raise the car.

14. Remove the centring fixture.

15. Fit the front exhaust pipe (A).


16. Fit the intermediate shaft (B) and the shaft bracket (A).

Tightening torque 24 Nm (18 lbf ft).


17. Fit the outer drive shaft.

Important

Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.


18. Tighten the bolts on the lower swivel joints (D).

Tightening torque 50 Nm (37 lbf ft)


19. Position the lower anti-roll bar links (B) and tighten them while gripping the flats with a thin spanner.

Tightening torque 64 Nm (47 lbf ft)

20. Position the outboard steering links and tighten them (A).

Tightening torque 35 Nm (26 lbf ft)

21. Certain cars: Fit the angle sensor bracket to the suspension arm. Secure the cable to the subframe and fit the connector (C) of the headlamp angle sensor.

22. Tighten the retaining bolts (B) of the A/C compressor and fit the A/C compressor connector (A).


23. Fit the multigroove belt (A) so that it follows the marked direction of rotation.


24. Connect the steering shaft (A) to the steering gear. Use Thread locking adhesive, Loctite 242 on the bolt.

Tightening torque: 30 Nm (19 lbf ft)


25. Lower the car.

26. Man: Fit the quick coupling (B) on the clutch slave cylinder. Remove the hose pinch-off pliers.


27. Man: Attach the gear cables (A) to the gearbox.

28. Aut: Position the hose (B) for automatic gearbox bleeding.


29. Aut: Attach the gear cable (A).

30. Attach the hose (D) of the rear radiator core.


31. Fit the quick coupling (B) and clips (C) to the EGR cooler's water port.

32. Attach the vent hose (A) to the engine.

33. Fit the connectors of the rear temperature sensor (B) and the particle filter pressure sensor (A).


34. Fit the following:

- Attach the connector (G) to the left structural member.


- Connect the ground cables (F).

- Attach the engine harness clamp (E) to the body.

- Fit the retaining bolt (D) of the engine harness connector in the electrical centre. Fit the connectors.

- Attach the positive cable (C) to the positive terminal of the battery.

- Fit the two retaining bolts (B).

- Fit the cover of the electrical centre.

- Fit the windscreen washer filler pipe (A).

35. Aut: Attach the oil pipes to the radiator.

36. Fit the following:

- Fit the upper radiator hose (F).


- Fit the bleeder hose (E) and clips.

- Attach the radiator fan connector (D) and clips.

- Fit the boost pressure valves (C).

- Fit the glow plug control module (B).

- Attach the hose with quick coupling (A) to the vacuum pump.

-
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.


37. Fit the turbo delivery pipe screw (B) to the fan cowling. Fit the turbo delivery hose's clip (A) to the throttle body.


38. Attach the fixings (B) of the engine control module wiring harness to the right structural member.


39. Fit the A/C pressure sensor (A) connector.

40. Fit the bracket (A) to the engine wiring harness.


41. Attach the intake fuel hose (B).

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.



42. Attach the return fuel hose (A).

43. Fit the air filter housing.

44. Fit the filter, air filter housing cover (D), hose (C), wiring harness (B) and mass air flow sensor connector (A).


45. Raise the car.

46. Fit the turbo delivery pipe screw (B) to the radiator and attach the hose clips (A).


47. Fit the left cover (A).


48. Fit the wiring harness cable tie (B) and fit the bracket (A) to the body.


49. Attach the lower radiator hose (B) to the radiator.


50. Attach the hose clip (A) of the air hose.

51. Fit the clip (C), engine control module connector (B) and cover (A).


52. Fit the Battery cover, lower section .

53. Raise the car.

54. Fit the front section of the left wing liner and the right wing liner (A).


55. Fit the Front bumper shell .

56. Lower the car slightly and mount the front wheels. See Wheels .

57. Lower the car and tighten the hub nuts of the drive shafts.

Tightening torque 230 Nm (170 lbf ft).

58. Fit the insulation and the upper engine cover.

59. Check oil level and top up as necessary. Fill with coolant to approx. 20 mm above the mark on the expansion tank. If a new engine is fitted, follow the instructions given in Filling and bleeding the cooling system, Z19DTR .

60. Aut : If the gearbox was drained, check the automatic transmission fluid level as described in Checking/adjusting oil level .

Man : Fill the gearbox with oil.

61. Remove the wing covers and restore the car's electrical functions, see After disconnecting the battery .