Intercooler - non air conditioning models

Refit

1. Clean mating faces of turbocharger and exhaust manifold.
2. Fit turbocharger to exhaust manifold, fit nuts and tighten to 25 Nm.
3. Fit RH under belly panel. See BODY, Repairs.
4. Fit bolt securing exhaust manifold to mounting bracket and tighten.
5. Clean mating faces of oil drail pipe and turbocharger.
6. Fit new gasket to turbocharger, fit bolts and tighten to 8 Nm.
7. Fit new manifold flange gasket.
8. Align exhaust front pipe, fit nuts and tighten to 25 Nm.
9. Remove stand(s) and lower vehicle.
10. Connect boost pressure sensing pipe to turbocharger.
11. Clean turbocharger oil feed pipe union and banjo bolt.
12. Fit new sealing washers to banjo bolt, connect oil feed pipe to turbocharger and tighten union to 18 Nm.
13. Connect air intake pipe to turbocharger and tighten clip.
14. Position turbocharger pipe and connect to turbocharger, tighten clip to secure.
15. Position engine lifting bracket and align turbocharger pipe to cylinder head.
16. Fit bolts securing turbocharger pipe and tighten to 25 Nm.
17. Fit bolt securing turbocharger pipe to front of cylinder head and tighten to 9 Nm.
18. Connect intercooler top hose to turbocharger pipe and tighten clip.
19. Position sound deadening pad to engine and secure with bolts.
20. Connect battery earth lead.

INTERCOOLER - NON AIR CONDITIONING MODELS

Service repair no - 19.42.15

Remove

1. Disconnect battery earth lead.
2. Raise front of vehicle.

WARNING: Support on safety stands.

3. Remove under belly panel. See BODY, Repairs.

4. Slacken hose clip and release hose from top of intercooler.

5. Slacken clip and release air hose from bottom of intercooler.