REMOVAL - REFITTING : VARIABLE GEOMETRY TURBOCHARGER (GARETT) :

DIESEL TURBO DV6TED4 FAP URGENT : Observe the safety and cleanliness instructions

1. Removing
Disconnect the battery . Remove the engine style cover . CAUTION : Protect the engine cooling radiator to prevent damage to the fins .

Remove the catalytic converter and particle filter assembly

CAUTION : Plug the turbo inlet and outlet openings . Remove : The air inlet sleeve from the turbocompressor The turbocharger noise attenuator

N.B. : Remove the turbocharger noise attenuator pivoting it in the centreline of the turbocharger manifold .

Figure : B1BM1FCD

Remove : The bolts (1) The heat shield (2) Uncouple the vacuum pipe (3) ( At "a" ) .

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Figure : B1HM0YXD

CAUTION : Keep the filling cylinder full . Uncouple the lubrication return pipe (5) ( At "b" ) . CAUTION : When slackening the unions, ensure that they do not rotate ( Support them if necessary ) . Remove the lubrication pipe (6), allen screws (4) and ring seals assembly .

Figure : B1FM03BD

N.B. : Check there is no strainer present at "c" on the bolt (4b) . Remove ( If necessary ) ; By means of a screwdriver .

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Figure : B1HM0YYD

Remove : The bolt (7) The nuts (8)

Figure : B1HM0YZD

Remove : The nuts (10) The turbocharger (9) CAUTION : Protect : The exhaust manifold ; Using the closer .

2. Checks
Examine the engine air filtering system . Check : The air hoses The condition and the correct positioning of the turbocharger vacuum pipe. Check the absence of foreign bodies in the following components : Induction circuit Exhaust gas manifold (it may cause the destruction of the turbocharger when operating it) Clean the surface of the turbocharger exhaust manifold . Check that the oil circuit unions are clean . CAUTION : Use the recommended bolts and nuts (heat resistant) . Replace : The turbocharger securing nuts The turbocharger lubrication banjo bolt copper seals The catalytic converter clips

3. Refitting
CAUTION : On refitting, all of the seals removed must be replaced with new seals . CAUTION : On removal : Remove the blanking pieces on the turbocharger at the last moment .

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Figure : B1HM0Z0D

Replace the seals "d" and "e" of the turbocharger .

Figure : B1HM0Z1D

CAUTION : Clean the joint faces with an approved descaling product . Do not use abrasives or sharp tools on the joint faces . The contact faces should not carry any trace of impact or scratching . CAUTION : Pre-fit the turbocharger components, to adjust their position ( Before tightening completely ) . CAUTION : Always renew : The nuts (8), (10) and the bolt (7) . Couple the turbocharger to the exhaust manifold . Fix : The nuts (8), (10) (new nuts) The bolt (7) (new) Put the lubrication pipe (9), allen screws (7) and ring seals assembly in place (new) . Tighten : The nuts (8), (10) to 2,6 0,6 daNm The bolt (7) to 2,5 0,3 daN.m CAUTION : On refitting, lubricate the end of the lubrication return pipe using engine oil . Recouple : The lubrication return pipe (5) The vacuum pipe (3) ( At "a" )

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Figure : B1BM1FDD

Method for tightening the upper union : Put an "A" = 8,5 mm diameter pin in place vertically ; As indicated above Tighten the bolt (4a) supporting the union using the pin ; Tighten to 3 daNm 0,45 daNm

Figure : B1BM1FED

Method for tightening the lower union : Put a "B" = 7,5 mm diameter pin in place horizontally ; As indicated above Tighten the bolt (4b) supporting the union using the pin ; Tighten to 3 daNm 0,45 daNm

Figure : B1HP2SWD

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"C" Incorrect fitting of the lubrication pipe . "D" Correct fitting of the lubrication pipe . "F" Authorised angle of movement : 3 (0 ; +0,2) . CAUTION : Placing the lubrication pipe under stress will result in engine oil leaks ; After tightening the unions, check that the lubrication pipe moves freely ; Otherwise, repeat the unions tightening operation and replace the seals . CAUTION : Carry out a pre-fitting to adjust the position of the catalytic converter and particle filter assembly .

Refit the catalytic converter and particle filter assembly Fit : The heat shield (2) The bolts (1) The turbocharger noise attenuator The air inlet sleeve from the turbocompressor

Figure : B1HM0ZND

Tighten : The bolt (11) to 1 0,1 da.Nm The shoulder bolt (12) ; To 0,5 0,1 daNm Connect the battery . CAUTION : Perform the operations to be carried out following reconnection of the battery .

4. Precautions to be taken before starting the vehicle

Disconnect the connectors of the diesel injectors . Turn the engine over with the starter motor for 15 seconds . Reconnect : The diesel injector connectors . Let the engine turn at idle for 30 seconds, before increasing the load . After the starting up, check the tightness of the various hose connections . Clear the faults in the memory ; Using the diagnostic tool .

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