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PRE-RELEASE

EGR cooler, Z19DTR

EGR cooler, Z19DTR

Important

Always use wing covers when working in the engine bay.


To remove

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



1. Remove the upper engine cover and insulation.

2. Remove the Spoiler shield, front .

3. Drain the coolant, see Draining, cooling system

4. Remove the lower mounting of the turbocharger delivery pipe:


• Undo the hose clip (A) and detach the hose from the pipe (B).

• Then remove the bolt (C) of the turbocharger delivery pipe's lower mounting.

5. Lower the car.

6. Remove the battery tray.

7. Slacken the dipstick retaining bolt (A).


8. Remove the upper mounting of the turbocharger delivery pipe:


• Remove the upper bolt of the turbocharger pipe (A).

• Undo the hose clip at the throttle body (B).

• Lift out the pipe and hose assembly.

9. Remove the radiator hoses:


• Remove the hose clip and detach the hoses to the thermostat housing (A), thermostat housing (B) to radiator core (C).

10. Remove the throttle body and unplug connectors.

Important

Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to Connectors, handling and inspection .



• Remove 3 bolts to the throttle body (A).

• Unplug the connector on the throttle body (B)

• Remove the coolant temp. sensor (C).

• Remove the solenoid valve (D) and EGR valve connector (E).

11. Unscrew the bolt (A) to the gearbox so that the EGR cooler can be lifted out.

Use swivel head wrench DT-48783.


12. Remove the exhaust return metal pipe.


• Remove the 3 upper (A) bolts.

• Remove the 2 lower bolts (B).

• Guide out the pipe by angling it in the upper mounting. Pay attention to the gasket and note its position.

13. Detach the radiator hose (A) from the EGR valve. New illustration.


14. Remove the bolts (A) on the bracket at the starter motor.


15. Detach vacuum hoses:


• Detach vacuum hoses (A) on the EGR cooler's vacuum tank, noting their position.

• Detach the vacuum hose (B) from the vacuum pump on the cylinder head.

• Lift the hose out of the circlip (C) that holds it to the wiring harness.

16. Remove the EGR cooler:


• Remove 2 bolts (A) and 2 nuts (B) holding the EGR cooler in place.

• Lift aside the wiring harness to make it possible to lift out the EGR cooler assembly.


To fit


1. Fit the EGR cooler:


• Position the EGR cooler.

• Fit 2 bolts (A) and 2 nuts (B) to hold the EGR cooler in place.

2. Screw in the bolt (A) of the gearbox.

Tightening torque 25 Nm (18 lbf ft)


3. Fit the bolts (A) on the bracket at the starter motor.


4. Attach the radiator hose (A) to the EGR valve.


5. Fit the EGR metal pipe.


• Position the new pipe, fitting a new gasket at the bottom. Apply Vaseline to the upper mating face.

• Fit the 2 lower bolts (B).

• Fit the 3 upper (A) bolts.

6. Attach radiator hoses:


• Attach the hoses to the thermostat housing (A) and fit the clip.

• Fit the thermostat housing (B) and its clamp.

• Attach the quick coupling to the radiator core (C).

Important

Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to Connectors, handling and inspection .


7. Fit the throttle body and plug in connectors.


• Plug in the connector on the throttle body (B)

• Position the throttle body and fit 3 bolts (A).

• Plug in the coolant temp. sensor connector (C).

• Fit the solenoid valve (D) and EGR valve connector (E).

8. Attach vacuum hoses:


• Attach 2 vacuum hoses (A) on the EGR cooler's vacuum tank, noting their position.

• Attach the vacuum hose (B) to the vacuum pump on the cylinder head.

• Fit the hose to the clip (C) on the wiring harness.

9. Fit the screw (A) for the dipstick.


10. Fit the upper mounting of the turbocharger delivery pipe:


• Attach the turbocharger pipe to the throttle body and fit the upper bolt (B).

• Fit the hose clip at the throttle body (A).

11. Raise the car.

12. Fit the lower mounting of the turbocharger delivery pipe:


• Attach the turbocharger pipe (B) to the charge air cooler and fit the lower bolt (C).

• Fit the hose clip (A) at the charge air cooler.

13. Fit the front spoiler shield.

14. Lower the car.

15. Fill with coolant, see Filling and bleeding the cooling system, Z19DTR .

16. Fit the battery tray.

17. Fit the insulation and the upper engine cover.


PRE-RELEASE