EGR cooler, Z19DTR
EGR cooler, Z19DTR |
Important | ||
Always use wing covers when working in the engine bay. |
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To remove |
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1. |
Remove the upper engine cover and insulation.
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2. |
Remove the
Spoiler shield, front
.
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3. |
Drain the coolant, see
Draining, cooling system
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4. |
Remove the lower mounting of the turbocharger delivery pipe:
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Undo the hose clip (A) and detach the hose from the pipe (B).
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Then remove the bolt (C) of the turbocharger delivery pipe's lower mounting.
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5. |
Lower the car.
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6. |
Remove the battery tray.
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7. |
Slacken the dipstick retaining bolt (A).
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8. |
Remove the upper mounting of the turbocharger delivery pipe:
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Remove the upper bolt of the turbocharger pipe (A).
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Undo the hose clip at the throttle body (B).
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Lift out the pipe and hose assembly.
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9. |
Remove the radiator hoses:
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Remove the hose clip and detach the hoses to the thermostat housing (A), thermostat housing (B) to radiator core (C).
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10. |
Remove the throttle body and unplug connectors.
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Remove 3 bolts to the throttle body (A).
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Unplug the connector on the throttle body (B)
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Remove the coolant temp. sensor (C).
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Remove the solenoid valve (D) and EGR valve connector (E).
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11. |
Unscrew the bolt (A) to the gearbox so that the EGR cooler can be lifted out.
Use swivel head wrench DT-48783. |
12. |
Remove the exhaust return metal pipe.
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Remove the 3 upper (A) bolts.
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Remove the 2 lower bolts (B).
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Guide out the pipe by angling it in the upper mounting. Pay attention to the gasket and note its position.
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13. |
Detach the radiator hose (A) from the EGR valve. New illustration.
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14. |
Remove the bolts (A) on the bracket at the starter motor.
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15. |
Detach vacuum hoses:
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Detach vacuum hoses (A) on the EGR cooler's vacuum tank, noting their position.
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Detach the vacuum hose (B) from the vacuum pump on the cylinder head.
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Lift the hose out of the circlip (C) that holds it to the wiring harness.
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16. |
Remove the EGR cooler:
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Remove 2 bolts (A) and 2 nuts (B) holding the EGR cooler in place.
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Lift aside the wiring harness to make it possible to lift out the EGR cooler assembly.
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To fit |
1. |
Fit the EGR cooler:
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Position the EGR cooler.
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Fit 2 bolts (A) and 2 nuts (B) to hold the EGR cooler in place.
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2. |
Screw in the bolt (A) of the gearbox.
Tightening torque 25 Nm (18 lbf ft) |
3. |
Fit the bolts (A) on the bracket at the starter motor.
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4. |
Attach the radiator hose (A) to the EGR valve.
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5. |
Fit the EGR metal pipe.
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Position the new pipe, fitting a new gasket at the bottom. Apply Vaseline to the upper mating face.
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Fit the 2 lower bolts (B).
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Fit the 3 upper (A) bolts.
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6. |
Attach radiator hoses:
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Attach the hoses to the thermostat housing (A) and fit the clip.
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Fit the thermostat housing (B) and its clamp.
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Attach the quick coupling to the radiator core (C).
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7. |
Fit the throttle body and plug in connectors.
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Plug in the connector on the throttle body (B)
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Position the throttle body and fit 3 bolts (A).
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Plug in the coolant temp. sensor connector (C).
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Fit the solenoid valve (D) and EGR valve connector (E).
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8. |
Attach vacuum hoses:
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Attach 2 vacuum hoses (A) on the EGR cooler's vacuum tank, noting their position.
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Attach the vacuum hose (B) to the vacuum pump on the cylinder head.
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Fit the hose to the clip (C) on the wiring harness.
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9. |
Fit the screw (A) for the dipstick.
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10. |
Fit the upper mounting of the turbocharger delivery pipe:
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Attach the turbocharger pipe to the throttle body and fit the upper bolt (B).
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Fit the hose clip at the throttle body (A).
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11. |
Raise the car.
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12. |
Fit the lower mounting of the turbocharger delivery pipe:
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Attach the turbocharger pipe (B) to the charge air cooler and fit the lower bolt (C).
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Fit the hose clip (A) at the charge air cooler.
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13. |
Fit the front spoiler shield.
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14. |
Lower the car.
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15. |
Fill with coolant, see
Filling and bleeding the cooling system, Z19DTR
.
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16. |
Fit the battery tray.
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17. |
Fit the insulation and the upper engine cover.
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