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Thread: Z19dt diesel turbo removal guide?

  1. #1
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    Vehicle : vectra c

    Trim : sri

    Engine : 1.8

    Year : 2008

    Default Z19dt diesel turbo removal guide?

    Hi all just wondering if I can find a guide to remove turbo from my 2006 diesel 120 z19dt? And would a turbo from a y20dth fit? Many thanks.

  2. #2
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    Vehicle : vectra

    Trim : vxr

    Engine : 2.8 v6 turbo

    Year : 2007

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    take the front of the car off lol its easyer although @nutron can do it with out and no it wont fit

  3. #3
    Regular Member SlowCoach's Avatar
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    Vehicle : SRI 150

    Trim : Smart and Bad!

    Engine : Z19DTH

    Year : 2008

    Mileage : 105000

    Default

    My how 2 should help. Same principle of getting into there. http://www.vectra-c.com/forum/showth...on-1-9cdti-150

    You need like for like turbo or uprated turbo for the right engine code.

    1- layout got to be the same,
    2- cant get other turbo from other different engine code as input and output will not work,

    Whoever or however gave u the expression that it could??

  4. #4
    Regular Member nutron's Avatar
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    Vehicle : Vauxhall

    Trim : very

    Engine : Z19DTH

    Year : Nosey

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    The manifolds are different because you only have four large exhaust ports rather than eight smaller ones. You could swap the core from one manifold to the other. Doing it without removing anything actually takes longer and you really need a ramp or it is a pig of a job.

  5. #5
    Regular Member AntSSSS's Avatar
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    Vehicle : Vectra Estate

    Trim : SRI

    Engine : CDTI 150 (Z19 DTH)

    Year : 2008

    Mileage : 100k

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    I changed @CH-VECTRA-ELITE only the other weekend.

    TBH its really not worth the hassle of doing it with the RAD pack still in place. Remove the bumper, crash bar and Rad pack and as @nutron says - its actually quicker.

  6. #6
    Regular Member C-Owner's Avatar
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    Just for fun here's the official way to do it.




    Remove

    1. Open bonnet

    2. Disconnect battery.

    3. Detach engine cover.
    • Unscrew 2x bolt

    • Unscrew oil filler cap

    • Remove engine cover

    • Screw in oil filler cap


    4. Remove pollen filter housing

    5. Drain coolant
    • Unscrew coolant compensation tank closure cap

    Warning: Only open coolant compensation tank once engine has cooled down

    • Place collecting basin underneath.

    • Open drain bolt (arrow)




    6. Detach vacuum line
    • Unscrew 2x bolt (arrows)

    • Disconnect 2x hose




    7. Remove charge air pipe (1)
    • Release 2x clamp




    8. Detach engine vent hose
    • Release clamp (1)




    9. Remove air intake hose (1)
    • Remove bolt

    • Release clamp


    10. Detach upper coolant hose
    • Release clamp


    11. Release oil dipstick guide tube at the top
    • Remove bolt (arrow)


    12. Remove connection hose from charge air pipe to intercooler
    • Release 2x clamp


    13. Detach cover
    • Unscrew 3x bolt


    14. Remove coolant pipe assembly (2)
    • Unscrew 5x bolt, nut

    • Release 5x clamps

    • Detach engine transport shackle,
    – Unscrew 2x bolt



    15. Release catalytic converter heat shield (3)
    • Unscrew 2x bolt




    16. Raise vehicle

    17. Detach lower engine compartment cover and right-hand engine splash protection if necessary

    18. Detach catalytic converter heat shield
    • Unscrew 2x nut, bolt
    Note: Unhook heat shield from stud bolt.


    19. Lower vehicle

    20. Remove catalytic converter heat shield

    21. Release metal pipe, exhaust gas recirculation (1)
    • Unscrew 2x bolt

    • Release clamp




    22. Raise vehicle

    23. Remove front exhaust pipe
    Important: When removing the central silencer, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the part of the exhaust system remaining in the vehicle must be secured to prevent it sagging. To do this, the section of the exhaust system with the flex pipe contained in it can be fastened to the substructure of the vehicle with suitable means such as e.g. wire or the transportation fittings for a new flex pipe. Bends of as little as 5 - 10 degrees in the flex pipe can lead to damage resulting in total failure of the flex pipe.

    • Unscrew 6x nut

    • Release exhaust pipe bracket
    – Unscrew 2x bolt


    • Remove 2x gasket


    24. Release catalytic converter at the bottom
    • Unscrew 2x bolt (2), nut (3)


    25. Remove catalytic converter
    • Disconnect wiring harness plug (1)

    • Release clamp (arrow)




    26. Remove turbocharger oil return line (1)
    • Unscrew 4x bolt




    27. Detach turbocharger oil feed line (1)
    • Unscrew banjo bolt (2)
    – From cylinder block


    • Remove 2x seal ring




    28. Detach vacuum hose for waste gate unit

    29. Lower vehicle

    30. Remove exhaust manifold (1)
    • Unscrew 8x nut

    • Remove gasket.





    Install

    31. Cleaning work

    32. Install exhaust manifold
    Note: Pour 0.4ml clean engine oil into the oil feed line opening of the turbocharger
    • Replace 8x nut

    • Replace gasket

    • 8x nuts 25 Nm


    33. Raise vehicle

    34. Attach turbocharger oil feed line
    • Banjo bolt 15 Nm
    – At cylinder block


    • Replace 2x seal ring


    35. Install turbocharger oil return line
    • Replace 2x gasket

    • 2x bolts 9 Nm

    • 2x bolts 25 Nm


    36. Connect vacuum hose for waste gate unit

    37. Attach catalytic converter
    Note: Ensure correct positioning.
    • Screw on clamp lightly

    • Connect wiring harness plug.


    38. Attach front exhaust pipe
    • Replace 6x nut

    • Replace 2x gasket
    – 6x nuts 20 Nm


    • Fasten exhaust pipe bracket
    – Tighten 2x bolt



    39. Attach catalytic converter
    • Tighten clamp

    • Tighten 2x bolt, nut


    40. Lower vehicle

    41. Fasten metal pipe, exhaust gas recirculation
    • Replace gasket

    • 2x bolts 25 Nm

    • Tighten clamp


    42. Attach catalytic converter heat shield

    43. Raise vehicle

    44. Fasten catalytic converter heat shield
    • Tighten 2x nut, bolt


    45. Attach engine cover.

    46. Lower vehicle

    47. Fasten catalytic converter heat shield
    • Tighten 2x bolt


    48. Install coolant pipe assembly
    • Attach engine transport shackle.
    – Tighten 2x bolt


    • 5x bolt, nut 9 Nm

    • Secure 4x clamp


    49. Attach cover
    • 3x bolts 9 Nm


    50. Attach upper coolant hose
    • Fasten clamp


    51. Attach oil dipstick guide tube at the top
    • Bolt 9 Nm


    52. Install connection hose from charge air pipe to intercooler
    • 2x clamps 3,5 Nm


    53. Attach air intake pipe to turbocharger
    Important: Adhere to the following installation sequence

    • Place seal on the turbocharger connection

    • Attach air intake pipe
    – Tighten clamp 3.5 Nm


    • Tighten bolt 9 Nm


    54. Attach engine vent hose
    • Fasten clamp


    55. Fit charge air pipe
    • 2x clamps 3,5 Nm


    56. Attach vacuum line
    • 2x bolts 9 Nm

    • Connect 2x hose


    57. Install air cleaner housing

    58. Attach engine cover.
    • Unscrew oil filler cap

    • Place engine cover in position

    • Screw in oil filler cap

    • 2x bolts 9 Nm


    59. Connect battery.

    60. Program volatile memories

    61. Check engine oil level and correct if necessary.
    • Observe specified engine oil quantity


    62. Close bonnet

  7. Thanks JMo thanked for this post
  8. #7
    Regular Member Damo77's Avatar
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    Vehicle : Vectra

    Trim : SRi

    Engine : 1.9 CDTi 8v

    Year : 55

    Mileage : 92,000

    Default

    Quote Originally Posted by C-Owner View Post
    Just for fun here's the official way to do it.




    Remove

    1. Open bonnet

    2. Disconnect battery.

    3. Detach engine cover.
    • Unscrew 2x bolt


  9. #8
    Regular Member C-Owner's Avatar
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    Default

    Quote Originally Posted by Damo77 View Post

    I did say
    "for fun"



    So here the pictures just for fun ...........
    4.jpg1.jpg5.jpg2.jpg6.jpg3.jpg
    Last edited by C-Owner; 12th April 2013 at 13:12.

  10. #9
    Regular Member nutron's Avatar
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    Vehicle : Vauxhall

    Trim : very

    Engine : Z19DTH

    Year : Nosey

    Default

    Getting that heat sheild out is a pain in the hoop but I have done three, two Astras and one Vectra without removing the front end. I can now do the job on mine in 90-100 minutes but as with PaulHBs I usually allow 4-5 hours.

  11. #10
    Regular Member Teapot's Avatar
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    Vehicle InfoStats

    Vehicle : Signum

    Trim : Design+

    Engine : 1.9 CDTI 150

    Year : 2007

    Mileage : 101000

    Default

    Did turbo replacement on z19dt last summer. took only 5 hours with no prior experience. left rad pack and bumper in place, removed it from under the car. had to disconnect a couple of a.c. pipes but that was no problem as the condenser was knackered so there was no gas in it anyway.

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