Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the valve cover.
ENGINE - Td4, Inlet and outlet camshafts, Valve cover gasket.
3. To facilitate subsequent assembly, mark the EGR tube and heat exchanger.
4. Loosen the clamps securing the exhaust gas bypass tubes to the heat exchanger.
5. Remove the tube connecting the recirculation system heat exchanger to the recirculation valve.
6. Unscrew the bolt securing the fuel rail to the support bracket.
7. Loosen the bolt securing the turbocharger outlet hose to the support bracket.
8. Remove the lower engine guard.
EXTERIOR PARTS, REPAIR WORK, Lower engine protection shield.
9. Loosen the bolt securing the turbocharger outlet hose to the upper distribution pipe of the cooling system.
10. Unscrew the 2 bolts securing the tube bracket to the engine lifting eye and remove the bracket.
11. Loosen the clamp and remove the vacuum hose.
12. Unscrew the three bolts securing the exhaust gas cooling heat exchanger (recirculation system) to the cylinder head and to the eye.
13. Raise the heat exchanger above the bracket and place a container under the cooling system hoses to collect the coolant.
14. Loosen the clamps and remove the hoses from the heat exchanger, let the coolant drain.
15. Remove the exhaust gas recirculation (EGR) heat exchanger.
Installation
1. Install the cooling system heat exchanger, put on the cooling system hoses and install the clamps.
2. Install the recirculation system heat exchanger on the bracket, screw in the bolts and tighten them to a torque of 25 Nm.
3. Install the tube mounting bracket to the lifting eye, screw in the bolts and tighten them to a torque of 25 Nm.
4. Connect the vacuum hoses and tighten the clamps.
5. Screw in the turbocharger hose mounting bolt to the cooling system pipe and tighten it. Tightening torque 25 Nm.
6. Reinstall the lower engine guard.
EXTERIOR PARTS, REPAIR WORK, Lower engine protection shield.
7. Screw in the turbocharger outlet air hose mounting bolt to the support bracket and tighten it. Tightening torque 10 Nm.
8. Screw in the fuel rail mounting bolt to the support bracket and tighten it. Tightening torque 10 Nm.
(The article was copied from the website: www.lrman.ru)
9. Install the EGR tube onto the heat exchanger, but do not tighten until the valve cover is fully installed.
10. Put on the EGR pipe clamp and tighten the screw.
11. Install the valve cover.
ENGINE - Td4, Inlet and outlet camshafts, Valve cover gasket.
12. Connect the negative battery terminal.
13. Top up the coolant to the required level.
MAINTENANCE, Cooling system and intercooler.
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