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Spare part engine block, Z19 DT, to fit

Spare part engine block, Z19 DT, to fit

To fit


1. Unpack the spare parts.

2. Fit 32 025 020 Lifting eye if not already fitted.

3. Secure the engine in an engine lift.

4. Position the engine on a suitable work surface.

5. Remove the engine from the engine lift.

6. Fit the cover (G).


7. Fit the pressure plate, clutch disc and flywheel.

8. Fit the glow plug (E).

9. Fit the injectors (D).

10. Fit the oil level sensor (C).

11. Fit the crankshaft position sensor (B).

12. Fit the oil filter housing (A).

13. Fit the coolant pipe (A).


14. Fit the intermediate plate (C).


15. Fit the belt tensioner (A) and impeller (B) of the timing belt.

16. Fit the water pump (C).


- Fit the water pump (C) with camshaft position sensor (B).

- Fit the Allen bolt of the camshaft position sensor (B).

- Fit the plastic guard (A) of the camshaft position sensor.

17. Fit the camshaft sprocket (A) EN-46787 (1) and KM-956-1.

Important

Proceed with caution to ensure that the camshaft sensor is not damaged.



18. Fit the vacuum pump (C).


19. Fit the thermostat housing (B).

20. Fit the crankcase ventilation hose (A).

21. Fit the intake manifold.


- Fit the intake manifold (B).

- Remove the bleeder nipple of the thermostat housing (A).

22. Fit the high-pressure pump bracket (A).


23. Zero the engine.


- Fit special tool 32 025 009 Crankshaft fixing tool to the crankshaft (A).

- Check that the marking on the camshaft aligns with the marking on the camshaft cover (B).

24. Fit the belt.


- Remove special tool 32 025 009 Crankshaft fixing tool

- Position the belt as marked.

- Adjust so that the belt tensioner arrow is right in front of the mark by pressing the setting lever in the direction of the arrow. Tighten the belt tensioner using a large screwdriver and an M8 bolt for support.

Tightening torque 25 Nm (18 lbf ft)

- Turn the crankshaft 2 revolutions.

- Refit 32 025 009 Crankshaft fixing tool. Check that the belt is mounted correctly, that the camshaft sprocket marking is aligned with the marking on the camshaft cover and that the tension roller setting arrow is in the centre of the mark.

- Remove 32 025 009 Crankshaft fixing tool and fit the bolt on the oil pump.

25. Fit the lower timing cover (C).


26. Replace the timing cover (B)

27. Fit the crankshaft pulley (A).

28. Fit the glow plug wiring harness (A).


29. Fit the fuel rail.


- Fit the fuel rail (E).

- Attach the fuel pipe connections on the fuel rail (D).

- Attach the fuel pipe connection to the high-pressure pump (B).

- Attach the fuel pipe connections at the injectors (B).

- Fit the cable clip and move the cable aside (A).

30. Fit the EGR cooler.


- Fit the connection to the coolant pipe (F).

- Fit the nut on the thermostat housing (E).

- Fit the connection to the EGR valve (D).

- Fit the bolt on the cylinder head (C).

31. Cars with vacuum tank:

- Fit the bolts of the vacuum tank bracket (B).

- Fit the vacuum hoses' connection to the vacuum tank (A).

32. Fit the fuel lines.


- Fit the return fuel line to the fuel rail (D).

- Fit the pressure regulator (C).

- Fit the return fuel line to the fuel pump.

- Fit the return fuel lines to the injectors (A).

33. Fit the manifold.


- Fit the nuts and the manifold (D).

- Fit the turbocharger's oil return line to the engine block (C).

- Fit the turbocharger's oil line to the turbocharger on the engine block (B).

- Fit the EGR connection (A).

34. Fit the wiring harness.


- Position the wiring harness

- Fit the fuel pressure sensor on the fuel rail (F).

- Fit the throttle body (E).

- Fit the water temperature sensor on the thermostat housing (D).

- Fit the clip on the throttle body (C).

- Fit the intake manifold (B).

- Fit the injectors (A).

- Fit the fuel return line on the intake manifold bracket.

35. Fit the wiring harness


- Fit 3 clips (H).

- Attach the connector of:

- Oil level sensor (G)

- Crankshaft position sensor (F)

- Oil pressure sensor (E)

- Fuel rail (D)

- Fuel pump (C)

- Intake manifold temperature sensor (B)

- EGR valve (A)

36. Fit the wiring harness.


- Fit the cable in the groove (C).

- Fit the clip with the cable (B)

- Fit the wiring harness bracket (A)

37. Cars with vacuum tank/pipe: Attach the vacuum pipe.


- Fit the vacuum attachment on the vacuum pump (D).

- Fit the bolt on the camshaft cover (C).

38. Attach the vacuum hoses to the solenoid valve (B).

39. Fit the catalytic converter (A).

- Clean the sealing surfaces on the catalytic converter.

- Fit the catalytic converter using a new gasket. Hold the clamp open slightly with circlip pliers. Turn the clamp so that the nut points down (A).

Important

Tighten the clamp loosely, it must be possible to adjust the catalytic converter so that the lower bracket for the catalytic converter can be fitted later on.


40. Fit the heat shield (E).

41. Fit the dipstick with tube (D).

42. Fit the temperature sensor.


- Fit the temperature sensor (A).

- Connect and fit the connector (B).

- Fit the cable to the clip (C).

43. Fit the vacuum hose clips to the dipstick guide tube (F).

44. Fit the turbocharger intake manifold.


- Fit the intake manifold on the turbocharger and tighten the hose clips (D).

- Fit the bolt (B)

45. Fit the A/C compressor bracket (A).

46. Fit the belt tensioner (B) and the upper impeller (C).

47. Fit the alternator (A).


48. Fit the engine wiring bracket.


- Fit the bracket (B).

- Plug in the connector and fit the connector in the bracket (A).

49. Fit the gearbox (A).


50. Fit the catalytic converter bracket (A).


51. Fit the lower bolt of the starter motor (A).


52. Fit the coolant lines:


- Fit the bolt and the coolant line at the coolant pipe (F).

- Fit the bolt and the coolant line at the coolant pipe (E).

- Attach the coolant line at the thermostat housing (D).


- Attach the coolant line at the EGR cooler (C).

- Fit the bracket at the starter motor (B).

- Attach the coolant lines at the oil cooler (A).

53. Fit the engine wiring harness.

- Position the wiring harness on the engine.

- Automatic transmission: Plug in the TCM connector.

- Manual gearbox: Plug in the connector of the reversing light switch (F).


- Attach the ground cable (E).

- Attach the electrical connections of the starter motor (D).

- Attach the electrical connections of the alternator (C).

- Plug in the engine harness connector (B).

- Fit clips (A).

54. Raise the powertrain from the work area using an engine lift and 83 92 409 Lifting yoke .

55. Lift the powertrain to the subframe.

56. Fit the front torque arm (A) to the subframe.


57. Fit the rear torque arm (A) to the subframe.


58. Attach the electrical connections to the EHPS unit (A).


59. Remove 32 025 020 Lifting eye if fitted.

60. Fit the powertrain, see Powertrain.