TURBOCHARGER with CATALYTIC CONVERTER - R.R.

Operation 1064A11 · TURBOCHARGER ASSEMBLY

1.3 JTD 16V, 1.9 JTD 8V

Removing

Position the car on the ramp.

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal.

Carry out - 7055B54 under-engine guard - r r.

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

2. Loosen the band and disconnect the the turbocharger air inlet sleeve from the rigid pipe, air flow meter side.

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

2. Remove the air filter (2a) complete with air flow meter (2b) by releasing from the underlying pins and then from the rear fastening.

Undo the three fixing bolts (1a) and remove the heat shield (1b) for the engine oil cartridge filter.

1. Undo the nut (1a) and loosen the collar securing the exhaust pipe to the catalyzer (1b).

2. Release the exhaust pipe from the anchoring rubber blocks and disconnect the pipe from the catalyzer.

1. Undo the bolts (1a) and disconnect the air supply pipe between the turbocharger and the heat exchanger (1b), turbocharger side.

2. Remove the gasket.

3. Undo the bolts securing the engine oil return pipe from the turbocharger, engine crankcase side.

1. Loosen the band and disconnect the air inlet hose to the turbocharger, turbocharger side.

2. Undo the nuts (2a) and remove the exhaust manifold heat shield (2b) complete with engine lifting bracket (2c).

3. Undo the connector (3a) and disconnect the engine oil supply pipe to the turbocharger (3b), turbocharger side.

1. Undo the nuts fixing the turbocharger to the exhaust manifold.

1. Undo the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.

2. Remove the turbocharger (2a) complete with catalytic converter (2b), engine oil return pipe from the turbocharger (2c) and gasket.

Position the catalytic converter in a vice fitted with protective jaws.

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

2. Open the safety flange lugs.

3. Undo the bolts (3a) and detach the turbocharger (3b) from the catalytic converter (3c).

Remove the gasket.

Refitting

Place the gasket in its seating.

1. Assemble the turbocharger (1a) to the catalytic converter (1b) and tighten the bolts (1c) to the specified torque.

2. Tighten the safety flange lugs.

3. Fit a new engine oil return pipe from the turbocharger (3a) complete with new gasket in its seating on the turbocharger and tighten the bolts (3b) to the specified torque.

Remove the catalytic convereter from the vice.

Refit the turbocharger in its seating complete with catalytic converter, engine oil return pipe from the turbocharger and gasket.

Tighten the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.

1. Tighten the nuts fixing the turbocharger to the exhaust manifold to the recommended torque.

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

Replace the copper washers for the connector.

2. Refit the exhaust manifold heat shield (2a) in its seating complete with engine lifting bracket (2b) and secure it with iits nuts (2c).

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

Position the heat shield for the engine oil cartridge filter and tighten the fixing bolts.

Place a new gasket between the engine block and the turbocharger engine oil return pipe.

1. Tighten the bolt fixing the engine oil return pipe from the turbocharger, engine crankcase side, to the specified torque.

2. Connect the air supply pipe between the turbocharger and heat exchanger (2a), turbocharger side, complete with gasket (2b) and tighten the bolts (2c).

Connect the exhaust pipe to the catalyzer, making sure not to deform the flexible section.

Tighten the nut on the collar securing the pipe to the catalyzer.

Position the rubber blocks in the anchoring points on the exhaust pipe.

Posistion in its seating the air filter complete with air flow meter, engaging it in the rear attachment and then in the underlying pins.

Connect the flexible hose to the air intake on the crossmember and tighten the fixing band.

Connect the air intake hose to the turbocharger, air flow meter side, and tighten the fixing band.

Connect the electrical connection to the air flow meter.

Carry out - 7055B54 under-engine guard - r r.

Connect the battery negative terminal.

Remove the car from the ramps.