Engine and gearbox - models with air conditioning

Refit

1. Clean camshaft cover and mating face on camshaft carrier. Ensure bolt holes in camshaft carrier are clean and dry.
2. Fit new gasket to camshaft cover.

3. Fit camshaft cover and tighten bolts in sequence shown to 12 Nm.
4. Align brake servo vacuum pipe bracket to camshaft cover and secure with bolt.
5. Connect engine breather hose to camshaft cover and tighten clip.
6. Clean mating faces of plenum chamber and inlet manifold.
7. Fit new gasket to inlet manifold, fit plenum chamber and tighten bolts to 25 nm.
8. Fit bolt securing plenum chamber to camshaft cover bracket and tighten bolt to 10 Nm.
9. Align EGR recirculation pipe to plenum chamber, fit bolts and tighten to 10 Nm.
10. Connect intercooler bottom hose to plenum chamber and tighten clip.
11. Position pipe to turbocharger and connect hose, tighten clip.
12. Align turbocharger pipe to cylinder head, fit bolts and tighten to 10 Nm.
13. Connect intercooler top hose to turbocharger pipe and tighten clip.
14. Fit engine acoustic cover. See BODY, Exterior fittings.

ENGINE AND GEARBOX - MODELS WITH AIR CONDITIONING

Service repair no - 12.37.01.20

Remove

1. Raise front of vehicle.

WARNING: Support on safety stands.

2. Recover refrigerant from air conditioning system. See AIR CONDITIONING, Adjustments.
3. Drain cooling system See COOLING SYSTEM - ’L’ SERIES, Adjustments.
4. Drain gearbox oil. See MAINTENANCEMaintenance.
5. If required, drain engine oil. See MAINTENANCEMaintenance.
6. Fit new sealing washer to drain plug, fit drain plug and tighten to 25 Nm.
7. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs.
8. Remove engine acoustic cover. See BODY, Exterior fittings.

Models with Intercooler fitted.

9. Loosen clip and disconnect intercooler top hose from turbocharger pipe.
10. Loosen clip securing top hose to intercooler and remove hose.
11. Loosen clip and disconnect intercooler bottom hose from plenum chamber.
12. Loosen clip securing bottom hose to intercooler and remove hose.