VARIABLE GEOMETRY TURBOCHARGER EXHAUST MANIFOLD ASSEMBLY SLEEVELEADING TO EXHAUST PIPE R R

Operation 1064A24 · TURBO CHARGER ASSEMBLY

1.9 JTD 16V

Removing

Position the vehicle on the ramp

Proceed with removal

- 1016A10 sound-proofing cover - r + r

Proceed with removal

Proceed with removal

Op. 7055B54 UNDER-ENGINE GUARD - R R

1. Undo the bolts (1a) and remove the exhaust manifold heat shield (1b).

Op. 1088D24 RIGID PIPE FOR COOLANT INLET TO WATER PUMP - R + R

1. Undo the nuts (1a) and remove the upper exhaust manifold heat shield (1b).

1. Undo the nuts fixing the front section of the exhaust pipe to the catalytic pre-converter.

2. Undo the nuts fixing the front section of the exhaust pipe to the catalytic converter.

3. Remove the front exhaust pipe section complete with seals.

1. Disconnect the vacuum pipe from the turbocharger variable geometry control actuator.

2. Loosen the band and disconnect the air supply hose between the turbocharger and the heat exchanger, turbocharger side.

3. Loosen the band and disconnect the corrugated air intake sleeve to the turbocharger, turbocharger side.

1. Undo the bolts (1a) and the nuts (1b) fixing the catalytic preconverter mounting bracket.

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

1. Undo the connector (1a) and disconnect engine oil supply pipe to the turbocharger (1b), crankcase side.

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

2. Keep the catalytic preconverter mounting bracket.

1. Undo the nuts (1a) and remove the variable geometry turbocharger assembly (1b) complete with exhaust manifold (1c).

2. Remove the exhaust manifold gasket.

Refitting

1. Place an exhaust manifold gasket in the housing.

2. Place the variable geometry turbocharger assembly (2a) complete with exhaust manifold (2b) back in its housing and secure it using the nuts (2c).

Place the catalytic preconverter complete with mounting back in its housing and fasten it to the turbocharger using the collar.

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

Tighten the bolt fixing the enigne oil return pipe from the turbocharger, engine crankcase side.

Tighten the bolts and the nuts fixing the catalytic preconverter mounting bracket.

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

Connect the air supply hose between the turbocharger and the heat exchanger, turbocharger side, and secure with a band.

Connect the vacuum pipe from the turbocharger variable geometry control actuator.

1. Place the front section of the exhaust pipe with gaskets back in its housing.

2. Tighten the nuts securing the exhaust pipe front section to the catalytic converter to the specified torque.

3. Tighten the nuts fixing the front section of the exhaust pipe to the catalytic preconverter to the recommended torque.

Place the upper exhaust manifold heat shield back in its housing and fix it using the nuts.

Place the lower exhaust manifold heat shield back in its housing and fix it using the bolts.

Proceed with refitting

Op. 1088D24 RIGID PIPE FOR COOLANT INLET TO WATER PUMP - R + R.

Proceed with refitting

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

Refill the engine cooling system with coolant

Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.

Proceed with refitting

- 1016A10 sound-proofing cover - r + r

Position the vehicle on the ramp