Exhaust Manifold With Turbocharger, Remove and Install

401221Exhaust Manifold with Turbocharger, Remove and Install
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Exhaust Manifold with Turbocharger, Remove and Install

Remove 1. Open bonnet 2. Empty climate control system Connect service station Blue hose on low pressure service connector (1) with small diameter Red hose on high pressure service connector (2) with large diameter Note: Read Service Station operating instructions carefully Determine quantity of condenser extracted at the oil separator of the Service Station
3. Disconnect battery 4. Remove bonnet (2)
file://C:\Program Files\cosids\DATA\TMP\00401221.rtf.html
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Remove oil filler cap (1) Pull off engine cover Note: Rubber retainers (3) must remain in cover 3 off Replace oil filler cap
5. Remove air cleaner housing (4) 1 wiring harness plug (1) 1 fastening bolt (3) Air intake manifold 1 clamp (2)
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6. Detach ribbed V-belt Mark direction of rotation Tension ribbed V-belt tensioner in direction of arrow using fastening bolt (1) Remove ribbed-V-belt
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7. Remove compressor (1) Remove coolant lines 1 fastening bolt 1 wiring harness plug 3 fastening bolts Note: Note different bolt lengths
8. Remove compressor bracket (1) 3 fastening bolts
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9. Remove air intake manifold (1) Unclip wiring harness 3 clips 2 clips 2 fastening bolts
10. Raise vehicle 11. Remove lower engine compartment cover 2 fastening bolts (2) 2 body-bound rivets (1) and (3) 10 tightening bolts
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(4), (5), (6) and (7)
12. Place collecting basin underneath. 13. Drain coolant Open radiator drain plug Collect coolant Close drain plug 14. Detach lower coolant hose (1) from radiator to exhaust gas recirculator 1 clip
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15. Remove exhaust front end from starter cat 3 fastening bolts (1)
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16. Place collecting basin underneath. 17. Drain engine oil Open oil drain bolt (1) Replace seal Fit oil drain bolt Tightening torque 78.4 Nm
18. Remove dipstick guide tube from upper part of oil pan 2 fastening bolts (1)
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19. Detach oil return hose (1) From turbocharger 2 fastening bolts
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20. Detach turbocharger oil feed line (1) From cylinder block 1 fastening nut (2)
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21. Remove starter cat From bracket 2 fastening bolts (1)
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22. Lower vehicle 23. Remove dipstick guide tube holder (1) Unclip vacuum line 2 clips Remove dipstick guide tube 1 clip Detach from camshaft housing 2 fastening bolts
24. Remove charge air hose (1) From intercooler 1 clip From turbocharger 1 clip
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25. Remove upper coolant hose (1) from radiator to exhaust gas recirculator 1 clip
26. Remove vacuum hose Pull away from waste-gate unit (1)
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27. Remove exhaust manifold heat shield 4 fastening bolts (1)
28. Detach turbocharger oil feed line From turbocharger 1 hollow bolt (1)
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29. Remove exhaust manifold (1) with turbocharger. 2 fastening bolts 7 fastening nuts
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Install 30. Clean sealing surfaces. 31. Install exhaust manifold with turbocharger Note: Add 0.4 ml clean engine oil in the oil feed line opening Replace seal 2 fastening bolts Tightening torque 69 Nm 7 fastening nuts Tightening torque 69 Nm 32. Install turbocharger oil feed line Replace seals 2 off To turbocharger 1 fastening bolt Tightening torque 20.6 Nm
33. Fit exhaust manifold heat shield 4 fastening bolts Tightening torque 11.7 Nm 34. Attach vacuum hose to waste-gate unit 35. Attach exhaust gas recirculation heat exchanger Replace seals 2 off to exhaust manifold
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2 fastening bolts Tightening torque 28.5 Nm
to exhaust gas recirculator body 2 fastening bolts Tightening torque 28.5 Nm to camshaft housing 1 fastening bolt Tightening torque 24 Nm
36. Attach upper coolant hose to exhaust gas recirculation heat exchanger 1 clip 37. Fit charge air hose Important: The slot (1) must engage with the projection (2) To charge air cooler 1 clip Tightening torque 3.5 Nm To turbocharger 1 clip Tightening torque 3.5 Nm
38. Fit dipstick guide tube holder to camshaft housing 2 fastening bolts Clip in vacuum hose 2 clips Dipstick guide tube 1 clip 39. Raise vehicle 40. Mount the starter cat To bracket 2 fastening bolts 41. Install turbocharger oil feed line Replace seals
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2 off
To turbocharger 1 hollow bolt Tightening torque 20.6 Nm
42. Fit oil return hose Replace seal To turbocharger 2 fastening bolts 43. Fit oil dipstick entry pipe Replace seal to upper part of oil pan 2 fastening bolts Tightening torque 9.8 Nm
44. Install front exhaust pipe Replace seal to starter cat 3 new fastening nuts 45. Attach lower coolant hose to exhaust gas recirculation heat exchanger 1 clip Important: When installing make sure that the brake hose (8) is above the engine compartment cover 46. Install lower engine compartment cover 2 fastening bolts (2) 2 body-bound rivets (1) and (3) 10 tightening bolts (4), (5), (6) and (7) Tightening torque 5 Nm
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47. Lower vehicle 48. Install compressor bracket 3 fastening bolts 49. Install compressor To bracket 3 fastening bolts Tightening torque 19 Nm 1 wiring harness plug Remove coolant lines 1 fastening bolt Tightening torque 20 Nm
50. Fit dipstick guide tube holder to camshaft housing
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2 fastening bolts
Clip in vacuum hose 2 clips Dipstick guide tube 1 clip 51. Insert ribbed V-belt Note: Note the direction of running of the ribbed V-belt Tension ribbed V-belt tensioner in direction of arrow using fastening bolt (1) and place ribbed V-belt in position I. Ribbed V-belt without air conditioning II. Ribbed V-belt with air conditioning
52. Install air cleaner housing 1 fastening bolt
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Tightening torque 15 Nm
Air intake manifold 1 clip Tightening torque 3.5 Nm 1 mass air flow meter wiring harness plug 53. Install air intake pipe. 2 clips Tightening torque 3.5 Nm 2 fastening bolts Clip wiring harness into position 3 clips 54. Install engine cover Remove oil filler cap Push in engine cover 3 rubber retainers Replace oil filler cap 55. Connect battery 56. Programme transient memory 57. Fill up engine oil, check oil level 58. Cooling System, Charge and Bleed 59. Top up climate control system Connect service station Blue hose on low pressure service connector (1) with small diameter Red hose on high pressure service connector (2) with large diameter Note: Read Service Station operating instructions carefully Use the Service Station to insert the quantity of new compressor lubricant into the climate control system that was extracted when it was emptied. Top up climate control system with coolant R 134a - coolant filling quantity 700g
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60. Close bonnet
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Exhaust Manifold With Turbocharger, Remove and Install

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Exhaust Manifold With Turbocharger, Remove and Install

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401221Exhaust Manifold with Turbocharger, Remove and Install