Contents: Dismantling ⇩ Assembly ⇩
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the valve cover with gasket.
TD6 ENGINE, REPAIR WORK, Valve cover gasket.
3. Remove the fan viscous coupling.
COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.
4. Unscrew the 3 bolts securing the EGR system heat exchanger.
5. Loosen the clamp securing the exhaust gas recirculation tube to the heat exchanger and remove the clamp from the heat exchanger.
6. Remove the 2 bolts securing the heat shield and the exhaust gas recirculation (EGR) pipe to the exhaust manifold.
7. Remove the heat shield from the manifold.
8. Remove the EGR pipe with the clamp.
9. Remove the 3 bolts securing the turbocharger to the exhaust manifold. Discard the gasket.
10. Unscrew the 12 exhaust manifold mounting nuts, remove the manifold and discard the gasket.
Assembly
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 N·m.
4. Install the turbocharger on a new gasket and tighten its mounting bolts. Tightening torque 50 Nm.
5. Wipe the EGR tube and mating surface.
6. Install the EGR tube, put on the clamp, but do not tighten it completely yet.
7. Place the heat shield on the manifold and tighten the exhaust gas recirculation (EGR) pipe and heat shield mounting bolts. Tightening torque 25 N·m.
8. Tighten the clamp securing the EGR system pipe to the system valve.
9. Tighten the exhaust gas recirculation (EGR) heat exchanger mounting bolts. Tightening torque 25 N·m.
10. Install the fan viscous coupling.
COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.
11. Install the valve cover with gasket.
TD6 ENGINE, REPAIR WORK, Valve cover gasket.
12. Connect the negative battery terminal.
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