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EGR cooler, Z19DT

EGR cooler, Z19DT

Important

Always use wing covers when working in the engine bay.


To remove

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


Warning

Exercise caution as the engine can be very hot.



1. Remove the upper engine cover and insulation.


2. Drain the coolant . Fit the spoiler.

3. Remove the exhaust return metal pipe between the throttle body and the EGR valve.


4. Remove the gasket.

Note

Make a note of the position of the gasket.


5. Remove the hose between the throttle body and the turbo delivery pipe.

6.
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 .


Remove the actuator connector.

7. Remove the actuator and the gasket.

8. Remove the exhaust return metal pipe.


9. Remove the coolant hose.


10. Remove the connector on the coolant temperature sensor.

11. Remove the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold. Move aside.

12. Detach the coolant line from the starter motor bracket.


13. Remove the coolant hose.

14. Remove the vacuum container.


15. Remove the crankcase ventilation hose from the camshaft cover and lower it.


16. Remove the exhaust return cooler.


To fit


1. Fit the exhaust return cooler.


2. Lift up the crankcase ventilation hose and fit it to the camshaft cover.

3. Fit the vacuum container.


4. Fit the coolant hose.


5. Fit the coolant line to the starter motor bracket.

6. Fit the coolant line to the reservoir from the engine, two mountings, and the hose to the manifold.


7. Fit the coolant pipe.

8.
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 .


Plug in the connector on the coolant temperature sensor.

9. Fit the coolant hose.

10. Fit the exhaust return metal pipe with new gaskets.


11. Clean the sealing surfaces for the actuator and fit with new gaskets.

Tightening torque 9 Nm (6 lbf ft).


12. Fit the exhaust return metal pipe between the throttle body and the EGR valve. Fit a new gasket in the same position as the old one.

13. Fit the hose between the throttle body and the turbo delivery pipe.

14. Fill with coolant .

15. Fit the insulation and the upper engine cover.