Engine Z16XE/Z18XE
1. Disconnect a wire from the negative plug of the storage battery.
2. Raise the car on a lift, drain the engine oil from the crankcase. Before screwing in the drain plug, be sure to replace the gasket.
3. Remove the multirib belt cover and exhaust system.
4. Disconnect the sensor for monitoring the level of impellent oil, remove 2 rubber plugs and unscrew those indicated on the resist. illustration fixing bolts and 12 bolts of fastening of the oil pan. Using a suitable tool, pry and disconnect the oil pan.
12.4 Sump (Z18XE engine) - the arrows indicate the bolts of the pan to the oil pump: 1. Rubber plugs; 2. Bolts of fastening to transmission; 3. Wiring connector for engine oil level sensor
5. Before installing the pallet, clean all mating surfaces of sealant residues and pre-thread all holes.
6. Apply a bead of sealant (gray color) thick 2.5-3.5 mm on the surfaces indicated on the resist. illustration and put the pallet back in place.
12.6 Apply fresh sealant before installing the pan (Z18XE engine)
Attention! Installation must be completed no later than 10 minutes after applying the sealant!
7. Install the remaining components in the reverse order of their removal.
Z22YH/Z22SE/Z20NET engines
8. Disconnect a wire from the negative plug of the storage battery, turn out a fixing bolt and remove a probe tube of measurement of level of impellent oil.
9. Raise the car on a lift and remove the multirib belt.
10. Drain the engine oil. Before screwing in the drain plug, be sure to replace the gasket.
11. Turn out 3 fixing bolts and remove the compressor, disconnect wiring of the gauge of control of level of engine oil.
12. Turn out bolts of fastening (see illustration) sump, use a suitable tool, pry the sump at the points indicated by the arrows and separate it from the engine block.
12.12 Fixing the oil pan (motors Z22YH/Z22SE/Z20NET)
13. Before installing the pallet, clean all mating surfaces of sealant residues and pre-thread all holes.
14. Apply a bead of sealant (gray color) thick 2.0-2.5mm on the surfaces indicated on the resist. illustration and put the pallet back in place.
12.14 Before installing the pallet, apply sealant to its mating surfaces (motors Z22YH/ Z22SE/Z20NET): Size I - 2.0-2.5 mm; Size II - 0.5-1.5 mm
Attention! Installation must be completed no later than 10 minutes after applying the sealant!
15. Tighten 15 bolts (see illustration) pallet fastening force 23 Nm, and then 2 bolts securing the pan to the transmission with a force 40 Nm.
12.15 Tightening order of the oil pan bolts (motors Z22YH/Z22SE/Z20NET): 1. Bolts of fastening to the engine block; 2. Engine oil level control sensor; 3. Transmission mounting bolts
16. Installation of other components is made in an order, the return to an order of their removal.
Z32SE engine
17. Raise the vehicle on a lift and remove the multirib belt cover.
18. Remove the exhaust system.
19. Drain the engine oil from the crankcase. Before screwing in the drain plug, be sure to replace the gasket.
20. Disconnect sensor wiring (see resist. illustration) engine oil level control, unscrew 3 bolts securing the sump to the transmission, and 17 bolts securing the block.
12.20 Fixing the oil pan (Z32SE engine)
21. Remove the pallet, be careful not to damage the mating surfaces. At the service station, the KM device is used for thisJ-37228.
22. Before installing the pallet, clean all mating surfaces of sealant residues and pre-thread all holes.
23. Apply a bead of sealant (gray color) thick 3.0-3.5mm on the surfaces indicated on the resist. illustration and put the pallet back in place.
Attention! Installation must be completed no later than 10 minutes after applying the sealant!
Tighten the bolts to the required torque.
12.23 Before installing the pallet, apply sealant to its mating surfaces (Z32SE engine): 1. Joints with the oil pump housing; 2. Cylinder block joints
24. Install the remaining components in the reverse order of their removal.
Z19DT engines (H)
25. Turn out a bolt and disconnect the top part of a tube of the dipstick of measurement of level of impellent oil.
26. Remove the intermediate drive shaft, cover the transmission hole with a suitable plug.
27. Remove the front section of the exhaust system, remove the 3 bolts and remove the catalytic converter mounting bracket.
28. Loosen the 4 crankshaft pulley bolts, remove the multi-ribbed belt and remove the pulley.
12.29 Bolts (2) bracket mounting (3) compressor (z19DT engine): 1. Wiring connector; 4. Guide roller
29. Disconnect the compressor wiring, remove the 3 bolts and remove the compressor, then remove the bolts (see illustration) fixing the compressor bracket and remove it together with the guide roller.
30. Drain the engine oil from the crankcase, disconnect the bottom of the engine oil dipstick tube and remove the tube.
12.31 Sensor (1) engine oil level control and return hose (2) lubrication systems (Z19DT engine)
31. Disconnect the wiring from the sensor (see illustration) check the engine oil level, remove the return hose of the engine lubrication system.
32. Turning the crankshaft in the direction of engine rotation (clockwise) install the engine flywheel so that through the holes in the flywheel you can unscrew the bolts securing the pan to the transmission. I use a special tool EN-46794, Turn out at first one bolt, once again turn a cranked shaft and turn out the second bolt.
33. Using a device EN47631 remove the 2 bolts securing the pan on the timing drive side.
34. Turn out the remained 10 bolts of fastening of the pallet crankcase and separate it from the block. Remove 2 bolts (see illustration) fixing the oil intake and remove the pan together with the oil intake from the engine.
12.34 Bolts (indicated by arrows) oil intake mounts (Z19DT engine)
35. Installation is carried out in the reverse order of removal. Be sure to replace all gaskets and seals.
Y20DTH/Y22DTR engines
36. Remove the engine cover, disconnect the EGR valve wiring and remove the oil filter.
37. Remove the crankcase protection and drain the engine oil.
38 Disconnect the wiring from the level control sensor and the engine oil temperature sensor (see illustration). Turn out 4 bolts of fastening of the pallet to transmission, and then 17 bolts of fastening to the block of the engine and remove the pallet. Remove pan gasket.
12.38 Pallet fixing (3) crankcase (motors Y20DTH/Y22DTR): 1. Engine oil temperature sensor; 2. Engine oil level sensor
39. If necessary, remove the 4 bolts and remove the oil pickup.
12.40 Places of application of sealant (motors Y20DTH/Y22DTR)
40. Installation is carried out in the reverse order of removal. Before installing the pallet, apply sealant to the joints of the engine block (see illustration). Don't forget to replace the seals.
Y30DT engine
41. Remove the subframe.
42. Remove the dipstick for measuring the level of impellent oil, remove the battery with a pallet, disconnect the upper part of the turbocharger air duct and take the air duct to the side.
43. Remove the expansion tank with hose. Release the engine wiring harness and move it to the side, freeing access to the turbocharger heat shield. Remove the 5 bolts/screws and remove the heat shield.
44. Having unscrewed 3 bolts, disconnect the front section of the exhaust system, remove the engine oil level dipstick tube, raise the car on a lift and drain the engine oil.
45. Turn out 2 bolts and remove an arm of fastening of the catalytic converter. Remove the front section of the exhaust system.
46. Loosen 2 nuts (see illustration) and remove the catalytic converter heat shield.
12.46 Nuts (indicated by arrows) catalytic converter heat shield fasteners (Y30DT engine)
47. Remove the intermediate drive shaft and shaft bracket.
48. Remove 16 bolts and 2 nuts and remove using KM-J-37228 (see illustration) bottom of the crankcase.
12.48 Lower part (1) sump (Y30DT engine)
49. Remove the tube of the dipstick for measuring the level of impellent oil. Disconnect the level sensor and engine oil temperature sensor wiring.
50. Loosen the mounting clamps and remove the crankcase ventilation hose.
51. Remove the front engine mount multirib belt.
52. Disconnect the compressor wiring (see illustration), turn out 3 bolts and remove the compressor.
12.52 Bolts (indicated by arrows) compressor mounts (Y30DT engine): 1, 2 Wiring connectors
53. Turn out 10 bolts of fastening of the top part of the pallet and remove it.
Note: The bolts have different lengths. Remember or mark the places of their installation.
54. When replacing the pallet, it is necessary to remove all removable elements from the old one and install on the new pallet.
55. Before installing the pallet, clean all mating surfaces of sealant residues and pre-thread all holes.
56. Apply a bead of sealant (gray color) thick 3.0-4.0mm on the surfaces indicated on the resist. illustrations and reinstall the drip tray.-
12.56a Places (indicated by an arrow) sealant application and tightening procedure for the upper part of the oil pan (Y30DT engine)
12.56b Places (indicated by an arrow) sealant application and tightening procedure for the lower part of the oil pan (Y30DT engine)
Attention! Installation must be completed no later than 10 minutes after applying the sealant! Tighten the bolts and nuts of the upper and lower parts of the pallet to the required torque in the order shown, the short and long bolts must be installed in their places.
57. Installation of other components is carried out in the reverse order of their removal.
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