- remove the front right wheel;
- remove the front right mudguard;
- remove the protective screens under the power unit;
- drain the oil from the gearbox;
Caution! Remove the intake pipe to avoid damaging the flexible link (bellows), which cannot withstand torsional, tensile or bending loads that may occur when dismantling one of the powertrain suspension elements.
- remove the lower reaction control arm;
- remove the right wheel drive;
Figure 4.120. Removing turbocharger pipes: 1, 3 - pipelines; 2 - bolt
- unscrew bolt 2 (figure 4.120);
- disconnect pipes 1 and 3;
Figure 4.121. Removing the exhaust gas recirculation valve: 1 - node; 2 - recirculation valve; 3, 4 - pipelines
- remove valve 2 (figure 4.121) exhaust gas recirculation;
- remove pipeline 3;
- remove node 1;
- remove pipeline 4;
- plug the turbocharger inlet and outlet necks;
Figure 4.122. Removing the turbocharger: 1 - knee; 2 - nuts; 3 - connecting nipple; 4 - turbocharger; 5, 7, 10 - bolts; 6, 9 - oil pipeline connections; 8 - support
- remove support 8 (figure 4.122);
- move aside the connection points of oil lines 6 and 9;
- remove knee 1;
- unscrew nuts 2;
- remove the clutch housing guard;
- tilt the engine forward;
- remove turbocharger 4.
Install the turbocharger in the following order:
- replace nuts 2 (see figure 4.122);
- install turbocharger 4;
- tighten the studs on the manifold to 10 Nm;
- tighten nuts 2 to 25 Nm;
- tighten bolts 5 to 12 Nm;
- tighten the connecting nipple 3 to a torque of 22 Nm;
- tighten bolts 10 to 23 Nm;
- install support 8;
- tighten bolts 7 to 23 Nm;
- tighten nipple 9 to 47.5 Nm;
- install connection 6 of the oil pipe in place;
Complete the installation in the reverse order of removal, following these requirements:
Figure 4.123. Installing the engine suspension reaction arm: 1, 3, 5 - bolts; 2 - nuts; 4 - reaction lever
- install the reaction lever 4 (figure 4.123) engine mounts;
- install right wheel drive;
- tighten bolts 1 and nuts 2 to 10 Nm;
- tighten bolt 5 to 50 Nm;
- tighten bolt 3 to 35 Nm;
- tighten the wheel drive shaft nut to 325 Nm;
- tighten the wheel bolts to 85 Nm;
Caution: Replace the exhaust system clamp regularly.
- install exhaust system components;
- fill the gearbox with oil;
- fill the engine cooling system and bleed air from it.