Removing
1. Disconnect the wire "masses" from the battery. For more information, refer to Specification
2. Remove the engine cover. For more information refer to Engine Cover - 2.7L Diesel (12.30.50)
3.
WARNING: Always plug all open connections to avoid contamination of the system.
Disconnect the brake booster vacuum line from the brake vacuum pump.
4.
WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.
Raise and support the vehicle.
5. Remove the exhaust system. For more information, refer to Exhaust System - Vehicle not included: Diesel Fuel Filter (30.10.08)
6. Lower the rear of the transmission to provide access.
7. Remove the left exhaust bypass pipe support bracket.
- Release the wiring harness from the mount.
- Turn out 3 bolts.
8. Remove the right exhaust bypass pipe support bracket. Turn out 3 bolts.
9. Remove the center support bracket for the exhaust bypass pipe. Turn out 2 bolts.
10.
CAUTION: Be careful when handling the bypass tube to prevent damage to the insulating material.
Disconnect the bypass pipe from the turbocharger.
- Remove the turbocharger heat shield bolt.
- Loosen and discard 3 nuts.
11. Remove the right exhaust manifold heat shield.
12. Remove the bypass pipe of the exhaust system.
- Loosen and discard 3 nuts.
- Remove and discard 2 gaskets.
13. Release the high pressure fuel supply line. Turn out a bolt.
14. Loosen the brake vacuum pump nut.
15. Remove the brake vacuum pump.
- Unscrew the pin.
- Turn out 2 bolts.
Installation
1.
CAUTION: When assembling, be very careful not to smear the sealant. If sealant smears, clean mating surfaces and apply new sealant.
Apply sealant at the two locations shown in the illustration.
- Make sure the vacuum pump seal is clean and dry.
- Make sure the cams on the vacuum pump are aligned with the camshaft.
- Apply 2 mm2 of Loctite 518 in the two locations shown.
- Install the brake vacuum pump immediately after applying the sealant.
- The vacuum pump of the brake system should be put on the engine in one motion, without smearing the sealant.
2. Install the brake vacuum pump.
- Screw in 2 bolts.
- Tighten the bolts (tightening torque 23 Nm).
3. Screw a hairpin of the vacuum pump of brake system. Tighten (tightening torque 13 Nm).
4. Screw the nut of the vacuum pump of the brake system. Tighten (tightening torque 13 Nm).
5. Attach the high pressure fuel supply line. Tighten the bolt to 10 Nm.
6. Install 3 new exhaust manifold studs. Tighten 3 studs (tightening torque 13 Nm).
7. Install 3 new turbocharger studs. Tighten 3 studs (tightening torque 13 Nm).
8.
CAUTION: Be careful when handling the bypass tube to prevent damage to the insulating material.
Install the bypass pipe of the exhaust system.
- Clean the mating surfaces of the elements.
- Install 2 new gaskets.
- Install 6 new nuts.
- Tighten 6 nuts (tightening torque 24 Nm).
9. Install the exhaust gas bypass pipe center support bracket. Screw in 2 bolts, but do not tighten them.
10. Establish the right support bracket of a bypass pipe of system of release of the fulfilled gases. Screw in 3 bolts, but do not tighten them.
11. Establish the left support bracket of a bypass pipe of system of release of the fulfilled gases. Screw in 3 bolts, but do not tighten them.
12. Tighten the exhaust gas bypass pipe support bracket bolts in the following sequence.
- Tighten the 2 bolts marked 1 (tightening torque 10 Nm).
- Loosen 2 bolts 90 degrees.
- Tighten the 2 bolts marked 3 (tightening torque 10 Nm).
- Loosen 2 bolts 90 degrees.
- Tighten the 4 bolts marked 2 (tightening torque 25 Nm).
- Tighten the 2 bolts marked 1 (tightening torque 25 Nm).
- Tighten the 2 bolts marked 3 (tightening torque 25 Nm).
- Attach the wiring harness.
13. Install the right exhaust manifold heat shield. Tighten 3 bolts (tightening torque 10 Nm).
14. Install the turbocharger heat shield. tighten bolt (tightening torque 10 Nm).
15. Install the exhaust system.
For more information, refer to Exhaust System - Vehicle not included: Diesel Fuel Filter (30.10.08)
16.
CAUTION: Plug all open connections to avoid contamination of the system.
Connect the brake booster vacuum line to the brake vacuum pump.
17. Install the engine cover. For more information refer to Engine Cover - 2.7L Diesel (12.30.50)
18. Connect wire "masses" to the battery. For more information refer to Specification.
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