PRE-RELEASE
Spare part engine, (complete engine), Z19DT
| Spare part engine, (complete engine), Z19DT |
| To remove |
| 1. |
Remove the power unit, see Power train removal.
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| 2. |
Fit
32 025 020 Lifting eye
if not already fitted.
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| 3. |
Remove the electrical connections from the EHPS unit (A).
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| 4. |
Remove the rear torque arm (A) from the subframe.
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| 5. |
Remove the front torque arm (A) from the subframe.
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| 6. |
Lift off the power unit from the subframe using
83 92 409 Lifting yoke
.
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| 7. |
Position the powertrain on a suitable work surface.
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| 8. |
Remove the engine wiring harness.
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| • |
Remove the clip (A).
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Unplug the engine harness connector (B)
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Detach the electrical connections of the alternator (C)
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Detach the electrical connections of the starter motor (D)
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| • |
Detach the ground cable (E)
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Manual gearbox:
Unplug the connector of the reversing light switch (F).
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| • |
Automatic transmission:
Unplug the TCM connector.
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| • |
Remove the wiring harness from the engine
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| 9. |
Detach the coolant lines.
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| • |
Detach the coolant lines at the oil cooler (A)
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| • |
Remove the bracket at the starter motor (B)
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Detach the coolant line at the EGR cooler (C)
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| • |
Detach the coolant line at the thermostat housing (D)
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| • |
Remove the bolt and the coolant line at the coolant pipe (E)
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Remove the bolt and the coolant line at the coolant pipe (F)
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| 10. |
Remove the starter motor (A).
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| 11. |
Remove the catalytic converter bracket (A).
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| 12. |
Remove the gearbox (A).
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| 13. |
Remove the engine wiring bracket.
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| • |
Open the clip and unplug the connector (A).
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Remove the bolts (B) and move the wiring aside
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| 14. |
Remove the alternator (A).
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| 15. |
Remove the belt tensioner (A) and the upper impeller (B).
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| 16. |
Detach the turbocharger intake manifold. Remove the A/C bracket (A).
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Detach the hose at the camshaft cover (C)
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Remove the bolt (B)
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Detach the hose clip at the turbocharger and remove the intake manifold (C)
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| 17. |
Remove the vacuum hose clips from the dipstick guide tube (F).
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| 18. |
Remove the temperature sensor.
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| • |
Remove the temperature sensor (A).
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Unplug the connector (B)
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Remove the cable and bracket (C)
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| 19. |
Remove the dipstick with tube (D).
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| 20. |
Remove the heat shield (E)
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| 21. |
Remove the catalytic converter (A)
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| 22. |
Detach the vacuum hoses from the solenoid valve (B).
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| To fit |
| 1. |
Unpack the spare parts.
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| 2. |
Secure the engine in an engine lift.
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| 3. |
Position the engine on a suitable work surface.
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| 4. |
Remove the engine from the engine lift.
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| 5. |
Attach the vacuum hoses to the solenoid valve (B).
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| 6. |
Fit the catalytic converter (A)
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| • |
Clean the sealing surfaces on the catalytic converter
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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)
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| 7. |
Fit the heat shield (E).
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| 8. |
Fit the dipstick with tube (D).
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| 9. |
Fit the temperature sensor
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| • |
Fit the temperature sensor (A).
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Connect and fit the connector (B).
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Fit the cable to the clip (C).
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| 10. |
Fit the vacuum hose clips to the dipstick guide tube (F).
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| 11. |
Fit the turbocharger intake manifold.
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Fit the intake manifold on the turbocharger and tighten the hose clips (C).
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Fit the bolt (B)
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| 12. |
Fit the A/C compressor bracket (A).
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| 13. |
Fit the belt tensioner (A) and the upper impeller (C).
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| 14. |
Fit the alternator (A)
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| 15. |
Fit the engine wiring bracket.
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| • |
Fit the bracket (B)
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Plug in the connector and fit the connector in the bracket (A)
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| 16. |
Fit the gearbox (A).
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| 17. |
Fit the catalytic converter bracket (A).
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| 18. |
Fit the lower bolt of the starter motor (A).
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| 19. |
Attach the coolant lines.
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| • |
Fit the bolt and the coolant line at the coolant pipe (F).
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Fit the bolt and the coolant line at the coolant pipe (E).
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Attach the coolant line at the thermostat housing (D).
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Attach the coolant line at the EGR cooler (C).
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Fit the bracket at the starter motor (B).
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Attach the coolant lines at the oil cooler (A).
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| 20. |
Fit the engine wiring harness.
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| • |
Position the wiring harness on the engine
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Automatic transmission:
Plug in the TCM connector
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Man:
Attach the connector of the reversing light switch (F).
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Attach the ground cable (E).
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Attach the electrical connections of the starter motor (D)
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Attach the electrical connections of the alternator (C)
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Plug in the engine harness connector (B)
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Fit the clip (A).
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| 21. |
Raise the powertrain from the work area using an engine lift and
83 92 409 Lifting yoke
.
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| 22. |
Lift the powertrain to the subframe.
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| 23. |
Fit the front torque arm (A) to the subframe.
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| 24. |
Fit the rear torque arm (A) to the subframe.
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| 25. |
Attach the electrical connections to the EHPS unit (A).
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| 26. |
Remove
32 025 020 Lifting eye
if fitted.
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| 27. |
Fit the powertrain, see Powertrain, to fit.
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