Air charge

PRECAUTIONS TO OBSERVE

Strictly observe the following points when working on the turbocharger:

• Clean the fittings and the surrounding area before unscrewing the parts.
• Place the removed parts on a clean surface and cover them (preferably with plastic sheet or paper; avoid lint-producing rags).
• Only remove replacement parts from their packaging at the last moment.
• Do not use parts that have been kept outside their original packaging.
• Avoid using compressed air, which can carry dust that is harmful to the parts.

AIR-TO-AIR INTERCOOLER

REMOVAL AND REFITTING

• Remove the front bumper.
• Disconnect the hoses (1) from the air-to-air intercooler (2) (Fig.55).

Fig. 55

• Lower the clips (3).
• Tilt the air-to-air intercooler (2) forward and lift it out of its mountings.

When refitting, observe the specified tightening torques.

TURBOCHARGER

REMOVAL

The turbocharger is removed together with the intake manifold; they are separated from each other on the workbench.

• Remove (Fig.56):

• the air filter housing (1),
• the electric cooling fan,
• the pre-catalytic converter (2),
• the air hose (3),
• the air vacuum hose (4).

• Remove (Fig.57):

• the oil supply pipe (5),
• the bracket (6),
• the air hose on the silencer (7).

• Under the vehicle, remove (Fig.58):

• the heat shield (8),
• the bolts (9),
• the turbocharger (10).

INSTALLATION

Observe the following points:

• only tighten the oil pipes once the turbocharger is tightened,
• the specified tightening torques,
• replace all seals,

Fig. 56

Fig. 57

Fig. 58

• check that there are no foreign objects in the intake duct and in the exhaust manifold,
• make sure the oil fittings are clean,
• make sure the turbocharger oil lines have no leaks and are not blocked; otherwise replace them,
• check the engine oil level and correct it if necessary,
• check for oil leaks.

Air intake

1. 1
   Air filter housing
2. 2
   Brackets
3. 3
   Bolt/nut: 1.2 daN.m
4. 4
   Air intake
5. 5
   Air filter
6. 6
   Air flow meter
7. 7
   Bolt/nut: 3 daN.m
8. 8
   Sealing gaskets
9. 9
   Turbocharger
10. 10
    Resonator
11. 11
    Oil supply pipe
12. 12
    Bolt: 1.5 daN.m
13. 13
    Heat shields
14. 14
    Screw: 1.4 daN.m
15. 15
    Bolt: 0.8 daN.m
16. 16
    Air-to-air intercooler
17. 17
    Exhaust manifold
18. 18
    Intake manifold
19. 19
    Engine stop motor
20. 20
    Exhaust gas recirculation valve actuator (with particulate filter)
21. 21
    Exhaust back-pressure sensor (with particulate filter)
22. 22
    Throttle valve actuator (with particulate filter) / Intake air throttle (without particulate filter)
23. 23
    Boost pressure sensor
24. 24
    Boost air temperature sensor
25. 25
    Water/EGR cooler.