HOSE CONNECTED to EXHAUST PIPE - R.R.

Operation 1064A19 · TURBOCHARGER ASSEMBLY

2.0 TB

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then open the boot, remove the cover on the left hand side and disconnect the negative battery lead.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

- Have a suitable container for collecting the coolant ready.

- Raise the lift.

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.

1. Disconnect the lower radiator pipe.

See in Op. 1080B40 CATALYTIC PRECONVERTER - R.R.

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.

See in Op. 1088E10 Radiator cooling FAN - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

1. Disconnect the turbocharger by-pass solenoid valve pneumatic connections.

1. Undo the fixing bolts (1a) and remove the protection (1b) for the sump oil return pipe from the turbocharger.

2. Disconnect the sump oil return pipe from the turbochager.

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

4. Undo the fixing bolts (4a) and nuts (4b) and remove the turbocharger mounting bracket (4c).

- Lower the lift.

1. Disconnect the turbocharger air inlet hose.

2. Disconnect the outlet hose from the turbocharger.

3. Disconnect the turbocharger coolant inlet (3a) and outlet (3b) pipes.

1. Undo the nuts fixing the exhaust manifold to the cylinder head.

2. Remove the turbocharger (2a) complete with exhaust manifold (2b).

3. Remove the exhaust manifold gasket from the studs on the cylinder head.

Refitting

- Fit the new exhaust manifold gasket in the special housing on the cylinder head.

- Fit the turbocharger-exhaust manifold assembly.

- Tighten the self-locking nuts fixing the exhaust manifold to the cylinder head.

- Fit the turbocharger reaction bracket and tighten the fixing bolts.

- Connect the turbochrger air inlet hose.

- Connect the air outlet hose from the turbocharger.

- Connect the turbocharger coolant inlet and outlet pipes.

- Connect the turbocharger fluid supply pipe connector.

- Connect the sump oil return pipe to the turbochager.

- Fit the protection for the turbocharger sump oil return pipe.

- Connect the turbocharger by-pass solenoid valve pneumatic connections.

See in Op. 1080B40 CATALYTIC PRECONVERTER - R.R.

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.

See in Op. 1088E10 Radiator cooling FAN - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.

- Connect the negative battery terminal, then close the boot.

See in Op. 0010T20 Engine REFRIGERANT FLUID - Change

- Remove the vehicle from the lift.