TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTING HOSE - R.R.

Operation 1064A19 · TURBOCHARGER ASSEMBLY

1.9 JTD 8V

Removing

Position the vehicle on the ramp.

Proceed with the removal

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R.

Proceed with the removal

Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..

1. Loosen the band (1a) and disconnect T connector (1b) from the turbocharger air intake hose.

1. Loosen the band (1a) and disconnect the corrugated air intake sleeve to the turbocharger (1b), turbocharger side.

1. Disconnect the electrical connection from the air flow meter.

1. Loosen collar (1a) and remove the air intake sleeves to turbocharger (1b) complete with air flow meter (1c).

1. Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.

Undo the upper nuts securing the exhaust manifold to the cylinder head.

1. Undo the nuts securing the exhaust pipe mount.

2. Undo nuts (2a), (2b) and remove the exhaust pipe attachment to the engine (2c) complete with mount (2d) and flexible mount (2e).

3. Remove the gaskets.

1. Loosen the collars and remove the air supply hose between the turbocharger and the heat exchanger.

1. Undo the nuts (1a), (1b) and remove the turbocharger bracket (1c).

1. Undo the bolts securing the engine oil return flange from the turbocharger.

1. Undo the connector (1a) and disconnect engine oil supply pipe to the turbocharger (1b), crankcase side.

1. Loosen the collar and disconnect the variable geometry turbocharger actuator control pipe, turbocharger side.

2. Loosen the band and disconnect the pipe to the turbocharger.

1. Undo the lower nuts securing the exhaust manifold to the cylinder head.

2. Remove the turbocharger (2a) with exhaust manifold (2b) and sleeve connected to exhaust pipe (2c).

3. Remove the exhaust manifold gasket.

Refitting

Refit the turbocharger complete with exhaust manifold, connection sleeve to exhaust pipe and exhaust manifold gasket.

Tighten the nuts fixing the exhaust manifold to the cylinder head to the recommended torque.

Connect the pipe to the turbocharger and tighten the band.

Connect the variable geometry turbocharger actuator control pipe, turbocharger side, and tighten the band.

1. Connect the engine oil delivery pipe to the turbocharger (1a), crankcase side, and tighten the connector (1b) to the recommended torque.

Tighten the engine oil return pipe flange bolts to the turbocharger.

Replace the protection for the engine oil return pipe from the turbocharger and fix it using the bolts.

Place the turbocharger mounting bracket back in its housing and secure it using the bolts.

Refit the air supply hose between the turbocharger and the heat exchanger and tighten the collars.

1. Place the exhaust manifold (1a), complete with gasket, back in its housing and fix it tightening the nuts (1b) and (1c) to the recommended torque.

2. Tighten the nuts securing the exhaust pipe mount.

Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.

Refit the air input hoses to the turbocharger complete with air flow meter and tighten the relevant bands.

Connect the electrical connection to the air flow meter.

Connect the air intake sleeve to the turbocharger, turbocharger side, and tighten the band.

Connect the T connector to the air intake sleeve to the turbocharger air intake hose and tighten the band.

Proceed with the refitting

Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..

Proceed with the refitting

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R.

Remove the car from the ramp.

Removing

Position the vehicle on the ramp.

Proceed with the removal

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R.

Proceed with the removal

Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..

1. Loosen the band (1a) and disconnect T connector (1b) from the turbocharger air intake hose.

1. Loosen the band (1a) and disconnect the corrugated air intake sleeve to the turbocharger (1b), turbocharger side.

1. Disconnect the electrical connection from the air flow meter.

1. Loosen collar (1a) and remove the air intake sleeves to turbocharger (1b) complete with air flow meter (1c).

1. Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.

Undo the upper nuts securing the exhaust manifold to the cylinder head.

1. Undo the nuts securing the exhaust pipe mount.

2. Undo nuts (2a), (2b) and remove the exhaust pipe attachment to the engine (2c) complete with mount (2d) and flexible mount (2e).

3. Remove the gaskets.

1. Loosen the collars and remove the air supply hose between the turbocharger and the heat exchanger.

1. Undo the nuts (1a), (1b) and remove the turbocharger bracket (1c).

1. Undo the bolts (1a) and remove the protection (1b) for the engine oil return pipe from the turbocharger.

1. Undo the bolts securing the engine oil return flange from the turbocharger.

1. Undo the connector (1a) and disconnect engine oil supply pipe to the turbocharger (1b), crankcase side.

1. Loosen the collar and disconnect the variable geometry turbocharger actuator control pipe, turbocharger side.

2. Loosen the band and disconnect the pipe to the turbocharger.

1. Undo the lower nuts securing the exhaust manifold to the cylinder head.

2. Remove the turbocharger (2a) with exhaust manifold (2b) and sleeve connected to exhaust pipe (2c).

3. Remove the exhaust manifold gasket.

Refitting

Refit the turbocharger complete with exhaust manifold, connection sleeve to exhaust pipe and exhaust manifold gasket.

Tighten the nuts fixing the exhaust manifold to the cylinder head to the recommended torque.

Connect the pipe to the turbocharger and tighten the band.

Connect the variable geometry turbocharger actuator control pipe, turbocharger side, and tighten the band.

1. Connect the engine oil delivery pipe to the turbocharger (1a), crankcase side, and tighten the connector (1b) to the recommended torque.

Tighten the engine oil return pipe flange bolts to the turbocharger.

Replace the protection for the engine oil return pipe from the turbocharger and fix it using the bolts.

Place the turbocharger mounting bracket back in its housing and secure it using the bolts.

Refit the air supply hose between the turbocharger and the heat exchanger and tighten the collars.

1. Place the exhaust manifold (1a), complete with gasket, back in its housing and fix it tightening the nuts (1b) and (1c) to the recommended torque.

2. Tighten the nuts securing the exhaust pipe mount.

Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.

Refit the air input hoses to the turbocharger complete with air flow meter and tighten the relevant bands.

Connect the electrical connection to the air flow meter.

Connect the air intake sleeve to the turbocharger, turbocharger side, and tighten the band.

Connect the T connector to the air intake sleeve to the turbocharger air intake hose and tighten the band.

Proceed with the refitting

Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..

Proceed with the refitting

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R.

Remove the car from the ramp.