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PRE-RELEASE

Valve housing cover Z19DTH

Valve housing cover Z19DTH

To remove


1. Position the wing cover. Engage gear position N and apply the parking brake.

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


2. Undo the expansion tank cap and release any overpressure.

3. Raise the car.

4. Remove the front spoiler shield (A).


5. CV: Remove Chassis reinforcement, front subframe, CV, diesel .

6. Remove the lower engine cover (B).

7. Position a receptacle under the car, connect a hose (A) and drain the cooling system.


Warning

The oil can be very hot if the car was recently driven. Risk of burn injuries.


8. Drain the transmission fluid.

• Position a receptacle under the car.

• Drain the transmission fluid via the drain plug (A). First remove the dipstick tube's plug (B) in order to access with an Allen key.

• Fit the drain plug with a new seal. Fit also the level plug.

Tightening torque, drain plug 45 Nm (33 lbf ft)


9. Remove the oil cooler hose connections from the gearbox. Plug the connections.


10. Remove the charge air pipe.

• Remove the charge air pipe's lower hose connection and turn it to the side (A).

• Remove the charge air pipe's lower retaining bolt (B).


11. Lower the car to the floor.

12. Remove the Battery and Battery cover, lower section.

13. Remove the charge air pipe (A).


• Remove 1 x clip to the coolant hose (B).

• Remove 1 x hose clip (C).

14. Detach the bracket to the engine wiring harness on the left-hand side of the body (C).


15. Remove the coolant hoses

• Remove 2 x hose clips (A)

• Remove the air exhaust hose from the radiator. (B)

16. Disconnect the oil pipes from the cooler's connections.

• Remove the dust cover for the upper pipe (A).

• turn 87 92 806 Removal tool, oil pipe automatic transmission slightly and detach the upper connection (A). At the same time, undo the pipe from the clip.


17. Remove the dust cover for the lower pipe (B) from the oil cooler. Use the removal tool for the oil pipe as above.

18. Remove the holder for the connectors and undo the wiring harness

• Unplug 1 x connector. (A)


• Remove 2 x nuts (B).

• Remove 1 x cable tie. (C)

• Unplug 1 x connector (D).

• Remove 1 x mounting (E)

19. Hold the wiring harness away with 83 95 212 Strap . (A)


20. Remove the valve housing cover.


• Remove the two upper screws (A) for the valve housing cover

• Raise the car and remove the remaining screws for the valve housing cover

• Remove the cover (B) using a screwdriver.

Important

The valve housing must be removed in order to avoid contaminants during the cleaning of sealing surfaces.


• Remove Valve housing Z19DTH


To fit


1. Lower the car to the floor.

2. Clean the contact surfaces.

• Remove seal residue on the contact surfaces for the gearcase.

• Clean the sealing surfaces from oil and grease using suitable cleaning agent.


3. Fit the cover on the gearcase. If the cover is damaged then fit a new one.

• Apply a bead using 90 543 772 Silicone flange sealant onto the cover and fit the cover onto the gearcase.


• Tighten 2 x screws

4. Raise the car.

5. Fit and tighten the bolts alternately.

• Fit 9 x screws.

• Tighten 11 x screws alternately.

Tightening torque 13 Nm (10 lbf ft)

6. Fit the oil cooler pipes (A) to the gearbox.

• Fit 1 x nut.

Tightening torque 6 Nm (4 lbf ft)


7. Lower the car to the floor.

8. Fit the oil pipes in the oil cooler

• Fit the lower pipe (B). Press until the pipe snaps into its position.


• Press in the dust cover (B).

• Fit the upper pipe (A) into the holder and the oil cooler. Press the pipe until it snaps into its position.

• Press in the dust cover (A).

9. Fit the holder for the connector and the wiring harness.

• Plug in 1 x connector (D).


• Fit 1 x mounting (E).

• Fit 2 x nuts (B)

• Fit 1 x cable tie (C)

• Plug in 1 x connector (A)

10. Fit the clamp for the engine's wiring harness to the body (C). Connect the air exhaust hose to the radiator (B).


11. Fit the cooler hoses.

• Fit 2 x clips (A).

12. Fit the charge air pipe

• Position the charge air pipe

• Fit the screws for the charge air pipe's upper bracket (A).

• Fit 1 x hose clip (C).

• Fit 1 x clip to the coolant hose (B).


Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


13. Raise the car.

14. Fit the charge air pipe lower bracket.

• Fit 1 x screw (B).


15. Clean and fit the hose on the charge air pipe and tighten the hose clip (A).

16. Remove the plug from the dipstick tube (A)


17. Lower the car to the floor.

18. Fill with gearbox oil

• Remove the filler plug (A).


• Connect 87 92 822 Oil filling equipment to the oil filler hole.

• Fill with automatic transmission fluid in accordance with the specification, Weight, torque, fluid capacity and grade of fluid until the oil flows out of the oil plug's dipstick tube.

Important

Fill up with oil through the oil filler hole. Do not remove any other plugs from the top of the gearcase.


19. Raise the car and fit the plug (B) in the dipstick tube.


20. Lower the car to the floor.

21. Fill 1 litre of automatic transmission fluid in accordance with Weight, torque, fluid capacity and grade of fluid Fit the filler plug.

Tightening torque 30 Nm (22 lbf ft)

22. Tighten the charge air pipe's upper retaining bolt.

23. Fit Battery cover, lower section and Battery .

24. Test pressurise the cooling system in accordance with Cooling system, test pressurising.

25. Fill with coolant and bleed the cooling system, in accordance with Filling and bleeding the cooling system . Do not run the engine to operating temperature before checking the transmission fluid level.

26. Apply the parking brake and engage gear position P. Chock the wheels if a track lift is used. Connect an exhaust extractor.

27. Start the engine. Move the selector lever from P to D and then from D to P. Allow the selector lever to remain in each gear position (N and R) for at least 2 seconds while applying the foot brake. Repeat this procedure twice.

28. Connect Tech 2. Run the engine until the temperature reaches 35-45 °C in the "Read values" menu in TCM.

29. Raise the car with the gear selector lever in position P and the engine at idling speed. Remove the level plug and check the fluid level. Fill as necessary. Fit the plug when the fluid stops flowing.

Tightening torque 8 Nm (6 lbf ft)

30. Fit the front spoiler shield (A).


31. Fit the lower engine cover (B).

32. CV: Fit Chassis reinforcement, front subframe, CV, diesel .

33. Carry out Measures after disconnecting the battery .


PRE-RELEASE