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Intake manifold/seal, Z19DTR

Intake manifold/seal, Z19DTR

Important

Always use wing covers when working in the engine bay.


To remove


1. Remove High-pressure pump, Z19DTR .

2. Remove EGR cooler, Z19DTR .

Important

Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to Connectors, handling and inspection .



3. Unplug the intake air sensor connector (688) (A) and the glow plug connector (B).

4. Detach the cable duct.

• Remove 4 bolts (A).


5. Remove the coolant connection (A).


6. Remove the wiring harness mounting from the high-pressure pump holder.

• 2 bolts (B).

7. Remove the oil trap from the engine block.

• Remove the upper hose connection (C).

• Remove the clips (D).

• Remove 2 bolts (E).

• Move the oil trap aside.

8. Unplug the connector (A) of the combustion circulation actuator.


9. Remove the stud (A) holding the high-pressure pump in place. Lock two M8 nuts with each other and remove the bolt.


10. Remove the bolt towards the lifting eye (A).


11. Remove the intake manifold (B).


To fit


1. Fit the intake manifold (B) with new seals.

Tightening torque 27 Nm (20 lbf ft)


2. Fit the bolt towards the lifting eye (A).

3. Fit the stud (A).

Important

Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to Connectors, handling and inspection .



4. Plug in the connector (A) of the combustion circulation actuator.


5. Fit the oil trap to the engine block.


• Fit 2 bolts (E)

• Fit the upper hose connection (C).

• Fit the clips (D).

6. Fit the wiring harness mounting to the high-pressure pump holder.

• 2 bolts (B).

7. Fit the coolant connection (A).

8. Fit the cable duct.

• Fit 4 bolts (A).


9. Plug in the intake air sensor connector (688) (A) and the glow plug connectors (B).


10. Fit EGR cooler, Z19DTR

11. Fit High-pressure pump, Z19DTR .

12. Connect an exhaust hose and start the engine. Check there are no leaks. Connect the diagnostic tool and clear any DTCs.