Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Drain the coolant from the engine.
COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Draining coolant, flushing the system and filling.
3. Remove the valve cover with gasket.
ENGINE - Td4, Inlet and outlet camshafts, Valve cover gasket.
4. Loosen the clamp and disconnect the expansion tank hose from the cooling system distribution pipe.
5. Unscrew the bolt securing the fuel rail to the support bracket.
6. Loosen the bolt securing the turbocharger outlet hose to the support bracket.
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7. Loosen the clamps and remove the hose from the turbocharger outlet pipe.
8. Loosen the clamp securing the exhaust gas recirculation tube to the heat exchanger and remove the clamp from the heat exchanger.
9. Unscrew the three bolts securing the exhaust gas cooling heat exchanger (recirculation system) to the cylinder head and to the eye.
10. Loosen the bolt securing the turbocharger outlet hose to the cooling system distribution pipe.
11. Loosen the bolt securing the turbocharger outlet hose to the bracket on the exhaust manifold.
12. Remove the three bolts securing the heat shield to the cooling system distribution pipe.
13. Loosen the bolt, remove the coolant pipe from the thermostat housing and discard the gasket.
14. Remove the heat shield.
15. Remove the 3 bolts securing the turbocharger to the exhaust manifold. Discard the gasket.
16. Unscrew the 8 nuts and remove the exhaust manifold. Discard the gaskets.
Installation
1. Wipe the exhaust manifold and mating surface.
2. Install the exhaust manifold onto the cylinder head using new gaskets.
3. Screw on the exhaust manifold mounting nuts and tighten them. Tightening torque 24 Nm.
4. Install the turbocharger on a new gasket and tighten its mounting bolts. Tightening torque 50 Nm.
5. Clean the exhaust gas recirculation pipe and the counter-landing surface.
6. Install the heat shield.
7. Wipe the cooling system distribution pipe and mating surfaces.
8. Install a new seal on the coolant distribution pipe, install the pipe on the thermostat housing and tighten the bolt to 8 Nm.
9. Tighten the heat shield mounting bolts. Tightening torque 8 Nm.
10. Install the EGR heat exchanger and fuel rail and tighten the mounting bolts. Tightening torque 25 Nm.
11. Put on the EGR pipe clamp and tighten the screw.
12. Route the turbocharger outlet hose and secure it. Tightening torque for M8 bolts is 25 Nm, for M6 bolts - 10 Nm.
13. Screw in the fuel rail mounting bolt to the support bracket and tighten it. Tightening torque 10 Nm.
14. Connect the expansion tank hose to the distribution pipe and secure it with a clamp.
15. Install the turbocharger air outlet hose and tighten the clamps.
16. Install the valve cover with gasket.
ENGINE - Td4, Inlet and outlet camshafts, Valve cover gasket.
17. Connect the negative battery terminal.
18. Fill the cooling system with coolant.
COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Draining coolant, flushing the system and filling.
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