TURBOCHARGER with CATALYTIC CONVERTER - R.R.

Operation 1064A11 · Turbo charger assembly

1.3 JTD 16v

Removing

Remove the car from the ramps.

Disconnect the battery negative terminal.

1. Disconnect the electrical connection from the air flow meter.

2. Loosen the band and disconnect the air inlet hose to the turbocharger.

1. Remove the air filter (1a) complete with air flow meter (1b) by releasing from the underlying pins and then from the rear fastenings.

1. Loosen the collar (1a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (1b).

1. Undo the bolts (1a) and disconnect the air supply pipe between the turbocharger and the heat exchanger (1b).

2. Remove the gasket.

3. Undo the bolts securing the engine oil return pipe from the turbocharger.

1. Loosen the band and disconnect the air inlet hose to the turbocharger.

2. Undo the nuts (2a) and remove the exhaust manifold heat shield (2b) complete with engine lifting bracket (2c).

3. Undo the connector (3a) and disconnect the engine oil supply pipe to the turbocharger (3b).

1. Undo the nuts fixing the turbocharger to the exhaust manifold.

1. Undo the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.

2. Remove the turbocharger (2a) complete with catalytic converter (2b), engine oil return pipe from the turbocharger (2c) and gasket.

Position the catalytic converter in a vice fitted with protective jaws.

1. Undo the bolts (1a) and remove the engine oil return pipe from the turbocharger (1b).

2. Open the safety flange lugs.

3. Undo the bolts (3a) and detach the turbocharger (3b) from the catalytic converter (3c).

Remove the gasket.

Refitting

Fit the gasket in place.

1. Assemble the turbocharger (1a) to the catalytic converter (1b) and tighten the bolts (1c) to the specified torque.

2. Tighten the safety flange lugs.

3. Fit a new engine oil return pipe from the turbocharger (3a) complete with new gasket in its seating on the turbocharger and tighten the bolts (3b) to the specified torque.

Remove the catalytic convereter from the vice.

Refit the turbocharger in its seating complete with catalytic converter, engine oil return pipe from the turbocharger and gasket.

Tighten the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.

1. Tighten the nuts fixing the turbocharger to the exhaust manifold to the recommended torque.

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

Replace the copper washers for the connector.

2. Refit the exhaust manifold heat shield (2a) in its seating complete with engine lifting bracket (2b) and secure it using the nuts (2c).

3. Connect the air inlet hose to the turbocharger and tighten the band.

Place a new gasket between the engine block and the turbocharger engine oil return pipe.

1. Tighten the bolt fixing the engine oil return pipe from the turbocharger to the specified torque.

2. Connect the air supply pipe between the turbocharger and heat exchanger (2a) complete with gasket (2b) and tighten the bolts (2c).

Refit the rigid exhaust pipe section between the catalytic converter and the silencer and secure it using the collar.

Fit the air filter complete with air flow meter in place.

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

Connect the electrical connection to the air flow meter.

Connect the battery negative terminal.

Remove the car from the ramps.