PRE-RELEASE
Spare part engine block, Z19 DT, to remove
| Spare part engine block, Z19 DT, to remove |
| 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 clips (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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Man
: Unplug the connector of the reversing light switch (F).
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Aut
: 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 detach 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 (B) and the upper impeller (C).
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| 16. |
Remove the A/C compressor bracket (A).
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| 17. |
Remove the turbocharger intake manifold:
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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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| 18. |
Remove the vacuum hose clips from the dipstick guide tube (F).
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| 19. |
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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| 20. |
Remove the dipstick guide tube (D).
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| 21. |
Remove the heat shield (E).
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| 22. |
Remove the catalytic converter (A).
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| 23. |
Detach the vacuum hoses from the solenoid valve (B).
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| 24. |
Cars with vacuum tank:
Detach the vacuum pipe:
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Remove the bolt on the camshaft cover (C).
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Remove the vacuum attachment on the vacuum pump (D).
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| 25. |
Disconnect the wiring harness:
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Remove the wiring harness bracket (A).
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Open the clip and remove the cable (B).
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Remove the cable from the groove (C).
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| 26. |
Remove the following connectors:
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EGR valve (A)
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Intake manifold temperature sensor (B)
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Fuel pump (C)
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Fuel rail (D)
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Oil pressure sensor (E)
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Crankshaft position sensor (F)
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Oil level sensor (G)
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Remove the clips (H)
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| 27. |
Disconnect the wiring harness:
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Detach the fuel return line from the intake manifold bracket.
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Injectors (A)
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Intake manifold (B)
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Clip on the throttle body (C).
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Water temperature sensor on the thermostat housing (D)
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Throttle body (E)
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Fuel pressure sensor on the fuel rail (F)
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Disconnect the wiring harness
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| 28. |
Remove the manifold:
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Detach the EGR connection (A).
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Detach the turbocharger's oil line on the engine block (B).
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Detach the turbocharger's oil return line from the engine block (C).
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Remove the nuts and the manifold (D).
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| 29. |
Detach the fuel lines.
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Detach the return fuel lines from the injectors (A).
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Detach the return fuel line from the fuel pump.
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Remove the pressure regulator (C).
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Remove the return fuel line from the fuel rail (D).
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| 30. |
Cars with vacuum tank:
Detach the vacuum hoses' connection to the vacuum tank (A). Remove the bolts of the vacuum tank bracket (B).
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| 31. |
Remove the EGR cooler:
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Remove the bolt on the cylinder head.
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Detach the connection to the EGR valve (D).
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Remove the nut on the thermostat housing (E).
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Detach the connection to the coolant pipe (F).
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| 32. |
Remove the fuel rail:
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Remove the cable clip and move the cable aside (A).
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Detach the fuel pipe connections at the injectors (B).
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Detach the fuel pipe connection to the high-pressure pump (B).
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Detach the fuel pipe connections on the fuel rail (D).
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Remove the fuel rail (E).
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| 33. |
Disconnect the glow plug (A) wiring harness.
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| 34. |
Remove the crankshaft pulley (A).
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| 35. |
Remove the timing cover (B)
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| 36. |
Remove the lower timing cover (C).
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| 37. |
Relieve tension in the belt tensioner and remove the timing belt (A).
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| 38. |
Remove the high-pressure pump's bracket (A).
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| 39. |
Remove the intake manifold:
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Remove the bleeder nipple of the thermostat housing (A).
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Remove the intake manifold (B)
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| 40. |
Detach the crankcase ventilation hose (A).
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| 41. |
Remove the thermostat housing (B).
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| 42. |
Remove the vacuum pump (C).
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| 43. |
Remove the camshaft sprocket (A) EN-46787 (1) and KM-956-1.
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| 44. |
Remove the water pump (C).
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Remove the plastic guard (A) of the camshaft position sensor.
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Remove the Allen bolt of the camshaft position sensor (B).
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Remove the water pump (C) with camshaft position sensor (B).
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| 45. |
Remove the belt tensioner (A) and impeller (B) of the timing belt.
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| 46. |
Remove the intermediate plate (C).
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| 47. |
Remove the coolant pipe (A).
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| 48. |
Remove the oil filter housing (A).
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| 49. |
Remove the crankshaft position sensor (B).
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| 50. |
Remove the oil level sensor (C).
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| 51. |
Remove the injectors (D).
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| 52. |
Remove the glow plug (E).
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| 53. |
Remove the pressure plate, clutch disc and flywheel.
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| 54. |
Remove the cover (G).
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| 55. |
Lift the engine from the work area and remove
32 025 020 Lifting eye
if it was fitted.
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