300Tdi Discovery
19
FUEL SYSTEM
4
REPAIR
TURBOCHARGER ACTUATOR
Service repair no - 19.42.31
Remove
1. Remove exhaust manifold and turbocharger.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust Manifold - Tdi
2. Remove 2 nuts securing the actuator to the
turbocharger bracket.
3. Release clip and disconnect hose from actuator.
4. Remove and discard clip securing control lever
to wastegate spindle.
5. Remove turbocharger actuator.
Refit
6. Fit the replacement actuator and secure with
nuts.
7. Push the control lever as far as possible towards
the actuator and apply pressure to keep the
lever in this position.
8. Pressurise the actuator to 57 - 62 cm Hg and
hold this pressure.
CAUTION: Use only the threaded end of
the lever to make adjustments. Forcing the
complete lever in or out will change the
calibration with the possibility of damaging engine
boost.
9. Screw the lever in either direction until the eye
on the end will locate easily over the wastegate
spindle and secure with a new clip.
10. Release the pressure and tighten the locknut.
11. Refit exhaust manifold and turbocharger.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
TURBOCHARGER AND GASKET
Service repair no - Turbocharger - 19.42.01
Service repair no - Gasket - 19.42.25
Remove
1. Disconnect battery negative lead.
2. Remove air cleaner assembly.
See Air Cleaner
3. Remove exhaust manifold assembly.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust Manifold - Tdi
4. Remove and discard clip securing control lever
to wastegate spindle.
5. Remove 4 bolts and 2 clamp plates securing
turbocharger to exhaust manifold.
6. Remove turbocharger and discard gaskets.
Refit
7. Clean mating faces of turbocharger and exhaust
manifold.
8. Reverse removal procedure. Use new clip to
secure control lever to wastegate spindle.
Tighten to
45 Nm.
9. Check/top-up engine oil level.
