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PRE-RELEASE

Spare part engine block, Z19 DTH, to remove

Spare part engine block, Z19 DTH, to remove

To remove


1. Remove the power unit, see Power train removal.

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

3. Remove the electrical connections from the EHPS unit (A).


4. Remove the rear torque arm (A) from the subframe.


5. Remove the front torque arm (A) from the subframe.


6. Lift off the power unit from the subframe using 83 92 409 Lifting yoke .

7. Remove the electrical connections from the alternator (A).


8. Remove the electrical connections from the starter motor (A).


9. Unplug the connector for the TCM (A) and undo the clips (B).


10. Unplug the engine harness connector (A), remove the bracket (B) and clip (C).


11. Remove the wiring harness from the engine.

12. Remove the cable mounting (A) located on the coolant pipes/starter motor. Remove the starter motor (B).


13. Raise the unit for better access.

14. Remove the front catalytic converter bracket (A).


15. Aut : Undo the 6 bolts (A) holding the torque converter to the driver plate. Rotate the engine clockwise on the pulley centre bolt.


16. Man : Remove the gearbox bolts and lift it away from the engine.

17. Aut : Remove the gearbox bolts (A). Pull out the gearbox about 10 mm.


18. Undo the plug and press the torque converter against the gearbox, fit 87 92 574 Holder for holding the torque converter in place and remove the gearbox (A).


19. Remove the pipe (A) to the coolant reservoir.


20. Remove the coolant pipes (A) leading to the oil cooler.


21. Remove the EGR cooler (A) assembly.


22. Fit 83 92 987 Flywheel locking attachment (B) in the threaded hole in the oil sump so that the flywheel/driver plate (A) is locked.


23. Man : Remove the bolts holding the pressure plate and remove the clutch.

24. Man : Remove the clutch plate.

25. Remove the flywheel/driver plate (A).

26. Remove the flywheel locking attachment (B).

27. Remove the protective plate.


28. Fit 32 025 017 Holder engine in stand and 83 96 376 Adapter kit sockets x4 . Mount the engine on 78 74 878 Floor stand (A).


29. Drain the engine oil and remove the oil filter cap and the filter.


30. Undo the vacuum hose (A) from the diaphragm box.


31. Remove the bracket for the temperature sensor's connector:

- Unplug the connector (B)

- Detach the cable from the clip

- Remove the connector's bracket (B)

32. Remove the dipstick pipe (C).

33. Remove the heat shield (D)

34. Remove the turbocharger oil delivery line and return line from the engine block. (A)


35. Remove the turbo from the catalytic converter (B).

36. Remove the AC bracket (C).

37. Remove the alternator (A).


38. Remove the crankcase ventilation hoses from the engine, the oil sump and the oil filler connection pipe. Open the hose's clip. (A)


39. Remove the oil trap hose with quick coupling (B).

40. Undo the wiring harness from the bracket and unplug the combustion circulation connector.


41. Open the wiring harness clip (A).


42. Remove the bracket for the oil separator.


43. Remove the thermostat housing:

- Remove the bolts (A)


- Remove the hose from the thermostat housing (B)

- Unplug the connector (C)

44. Remove the crankshaft pulley (A).


45. Remove the idler pulley centre bolt on the lower timing cover (B). Use, for example, 2 screwdrivers to carefully prize off from two directions.

46. Remove the upper timing cover (C).

47. Remove the lower timing cover (D).

48. Undo the crankcase ventilation pipe and hose form the camshaft housing.


49. Reset the engine by removing the plug and fitting 32 025 008 Camshaft fixing tool (A). Turn the engine until the tool clicks and locks the exhaust camshaft.


50. Relieve tension in the belt tensioner and remove the timing belt (B). Mark the direction of rotation if the timing belt is to be refitted.

51. Remove the vacuum line from the cable jointing chamber.


52. Remove the engine wiring harness by unplugging the following connectors:

- Pressure switch, engine oil (44) (A)


- Level sensor, engine oil (243) (B)

- Crankshaft position sensor (345) (C)

- EGR solenoid valve (606) (D)

- Fuel quantity control valve, high-pressure pump (652b) (E)

- Throttle body actuator unit (604) (F)

- Intake air sensor (688) (G)

- Camshaft position sensor (555) (H)


- Injectors (206) (I)

- Fuel pressure sensor (653) (J)

- Fuel pressure control valve (652a) (K) (certain cars)

- Glow plug connector (L)

53. Remove the cable duct.

54. Lift off the wiring harness.

55. Remove the oil cooler:

- Detach the lower coolant connection to the oil cooler (A).


- Remove the oil cooler (B).

56. Remove the coolant pipe on the intake manifold (A)


Important

The return line must not be removed from the fuel return's damping housing. Otherwise it must be replaced.


57. Remove the return line, injector:

- Remove the clips (B)

- Remove the return line on the injectors (E)

58. Remove the fuel rail:

- Remove the high-pressure hose, fuel rail - high-pressure pump (D)

- Remove the high-pressure hoses to the injectors (C)

- Remove the return hose (A)


- Remove the screws that hold the fuel rail (B)

59. Remove the coolant pipe (A).


60. Remove the timing belt cover's holder (B).

Important

If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.


61. Remove the injectors:

Note

If the nozzles cannot be raised by hand, use 32 025 013 Injector removal tool with 83 90 270 Sliding hammer and 32 025 012 Sliding hammer adapter.


- Remove the injectors in the following order, 1-2-3-4. Illustration


- Remove the nut for the injector (A) holder.

- Lift up the injector (A) (small illustration)

62. Remove the glow plug (B).

63. Undo the nut on the high-pressure pump gear:

- Counterhold with tools KM-6347 and KM-956-1.


- Unscrew the nut (A)

64. Remove the high-pressure pump gear:

- Fit the tool 32 025 005 Puller .

- Pull away the high-pressure pump's drive wheel (A)


- Counterhold with an open spanner

65. Certain cars : Remove the bracket (A).


66. Remove the high-pressure pump:

- Remove the high-pressure pump's return hose (A)


- Remove the high-pressure pump (B)

67. Remove the high-pressure pump's bracket (A).


68. Remove the intake manifold with throttle valve module and EGR valve (A).


69. Remove the noise absorbing panel on the oil sump (A).


70. Remove the bracket to the exhaust pipe on the lower section of the rear edge of the oil sump (B).

71. Remove the coolant pump (A).


72. Remove the tension pulley (B).

73. Remove the idler wheel (C).

74. Remove the belt pulley using 32 025 006 Holding tool, crankshaft in combination with 83 95 360 Holding tool, crankshaft pulley (A).


75. Remove the engine cover bracket (A).


76. Remove tool 32 025 008 Camshaft fixing tool (B).

77. Fit 83 96 178 Lifting eyes (A).


78. Detach the engine from the engine stand.

79. Position the engine on a suitable surface.

80. Detach the engine lift from the engine and remove the lifting eyes from the engine.


PRE-RELEASE