TURBOCHARGER UNIT AND EXHAUST MANIFOLD - R.R.

Operation 1064A27 · TURBOCHARGER ASSEMBLY

1.9 JTD 8V, 1.9 JTD 16V

Removing

- Position the vehicle on a lift.

Op. 1084A16 OIL DIPSTICK PIPE - R.R

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

Op. 1088D14 UPPER RADIATOR COOLANT OUTLET HOSE - R.R.

Op. 1088D10 LOWER RADIATOR COOLANT OUTLET HOSE - R.R.

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

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

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 1080B64 CATALYTIC CONVERTER EXCESS TEMPERATURE THERMOCOUPLE - R + R

1. Undo bolts (1a), (1b) and remove the catalytic converter bracket (1c).

1. Loosen collar (1a) and remove catalytic preconverter (1b).

1. Loosen the collar and disconnect the air delivery sleeve between the turbocharger and the heat exchanger, turbocharger side.

2. Undo the bolts (2a) securing the engine oil return pipe from the turbocharger (2b), crankcase sump side.

3. Undo the connector (3a) securing the engine oil delivery pipe to the turbocharger (3b), crankcase side.

4. Disconnect the vacuum pipe from the variable geometry actuator.

1. Unscrew bolts (1a), loosen the band (1a) and remove the E.G.R. system water/exhaust gas heat exchanger inlet pipe (1c).

2. Remove the seals.

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

2. Remove the seal.

1. Working at the bench, undo the bolts (1a) and remove the turbocharger engine oil return pipe (1b).

- Remove the seals.

2. Undo the connectors (2a) and remove the engine oil supply pipe to the turbocharger (2b).

Refitting

1. Position the pipe carrying engine oil to the turbocharger (1a) in its housing and secure it tightening connectors (1b) to the recommended torque.

2. Position the engine oil return pipe from the turbocharger (2a) in its housing complete with gaskets and secure it by tightening bolts (2b) to the specified torque.

1. Place the gasket back in its housing.

2. Place turbocharger assembly (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

1. Refit the E.G.R. system water/exhaust gas heat exchanger inlet pipe (1a) with gaskets (1b), then secure with the collar and tighten bolts (1d) to the specified torque.

1. Connect the vacuum pipe to the variable geometry actuator.

2. Tighten the connector (2a) securing the engine oil delivery pipe to the turbocharger (2b), crankcase side.

3. Tighten the bolts (3a) securing the engine oil return pipe from the turbocharger (3b), crankcase side, to the specified torque.

4. Connect the air delivery sleeve between the turbocharger and the heat exchanger, turbocharger side, and tighten the collar.

1. Place the catalytic converter (1a) in its housing and secure it using the collar (1b).

- Place the catalytic converter bracket in its housing and secure it using the bolts.

Op. 1080B64 CATALYTIC CONVERTER EXCESS TEMPERATURE THERMOCOUPLE - R + R

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

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

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

Op. 1088D10 LOWER RADIATOR COOLANT OUTLET HOSE - R.R.

Op. 1088D14 UPPER RADIATOR COOLANT OUTLET HOSE - R.R.

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

Op. 1084A16 OIL DIPSTICK PIPE - R.R

- Remove the vehicle from the lift.