PRE-RELEASE
Fan cowling, Z19DTR
| Fan cowling, Z19DTR |
| To remove |
| 1. |
Remove the upper engine cover and insulation (A).
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Warning
| 2. |
Undo the expansion tank cap (B) to release pressure and then retighten the cap.
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| 3. |
Remove
Upper radiator member, Z19DTR
.
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| 4. |
Place a suitable receptacle under the radiator. Connect a hose (A) to the radiator (B) and drain the coolant.
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| 5. |
Remove the turbocharger delivery pipe's hose clip (A) and the pipe's screw (B) from the radiator.
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| 6. |
Lower the car.
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| 7. |
Remove the turbo delivery hose's hose clip (A) at the throttle body and the turbo delivery pipe's screw (B) from the fan cowling. Remove the pipe and hose assembly.
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| 8. |
Detach the upper radiator hose (A) and the bleeder hose (B) from the radiator and move them aside.
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| 9. |
Aut
: Remove the protection from over the upper quick coupling, undo the oil pipe's quick coupling using
87 92 806 Removal tool, oil pipe, automatic transmission
and detach the upper oil pipe from the radiator. Plug the pipe and quick coupling. Catch any oil spill.
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| 10. |
Insert bolts (A) in the radiator member mounting and fit two
83 95 212 Straps
(B) around the radiator, charge air cooler and condenser.
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| 11. |
Raise the car.
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| 12. |
Remove the lower radiator mountings (C).
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| 13. |
Lower the car.
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| 14. |
Remove the mass air flow sensor's hose clips (A).
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| 15. |
Remove the right headlamp's bolts (B) and undo the connector (C).
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| 16. |
Remove the bolt (A) of the turbocharger intake manifold holder.
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| 17. |
Remove the bolts (B) of the crankcase ventilation pipe.
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| 18. |
Unplug the connector (C) of the camshaft position sensor.
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| 19. |
Remove the bolts of the turbocharger delivery pipe (A) and the bolts (B) of the holder.
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| 20. |
Raise the pipe slightly and remove the hose clip (C) from the air hose.
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| 21. |
Unplug the connector (A) and remove the wiring harness clips (B) from the fan cowling.
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| 22. |
Remove the fan cowling bolts (C).
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| 23. |
Remove the bolt (D) and lift out the pipe (E) with stick.
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| 24. |
Remove the A/C pipe holder (F).
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| 25. |
Unplug the connector (G).
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| 26. |
Move aside the boost pressure valves (H).
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| 27. |
Carefully lift out the fan cowling, left side first.
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| To fit |
| 1. |
Carefully lift in the fan cowling, right side first.
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| 2. |
Plug in the connector (G).
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| 3. |
Fit the holder (F) to the A/C pipe.
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| 4. |
Fit the pipe (E) with stick and fit the bolt (D).
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| 5. |
Fit the fan cowling bolts (C).
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| 6. |
Plug in the connector (A) and fit the wiring harness clips (B) to the fan cowling.
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| 7. |
Fit the hose clip (C) and reposition the turbocharger delivery pipe. Replace the O-rings as necessary.
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| 8. |
Fit the bolts of the turbocharger delivery pipe (A) and the holder (B).
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| 9. |
Plug in the connector (C) of the camshaft position sensor.
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| 10. |
Fit the bolts (B) of the crankcase ventilation pipe.
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| 11. |
Fit the bolt (A) of the turbocharger intake manifold holder.
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| 12. |
Plug in the connector of the right headlamp (C) and fit the bolts (B).
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| 13. |
Fit the hose clips (A).
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| 14. |
Raise the car.
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| 15. |
Fit the lower radiator mountings (C).
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| 16. |
Lower the car.
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| 17. |
Undo the straps (B) and remove the bolts (A).
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| 18. |
Aut: Fit the upper oil cooler pipe.
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| 19. |
Attach the upper radiator hose (A) and bleeder hose (B).
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| 20. |
Fit the turbocharger delivery pipe bolt (B) to the fan cowling and fit the hose clip (A) at the throttle body.
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| 21. |
Raise the car.
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| 22. |
Fit the pipe's bolt (B) to the radiator and fit the turbocharger delivery pipe's hose clip (A).
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| 23. |
Fit
Upper radiator member, Z19DTR
.
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| 24. |
Fill with coolant, see
Filling and bleeding the cooling system, Z19
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| 25. |
Pressure test the cooling system, see
Cooling system, pressure testing
.
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| 26. |
Fit the insulation and upper engine cover..
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