Table of contents: Removal 🠇 Installation 🠇
Removal
1.9 liter engines
1. Remove the intake manifold.
2. Remove the turbocharger.
3. On some models, remove the bolt from the exhaust pipe flange.
4. Remove the six exhaust manifold mounting nuts.
5. Remove the exhaust manifold from the cylinder head together with the gasket.
6. The studs that were unscrewed from the cylinder head when unscrewing the nuts should be screwed back in after removing the manifold.
2.1 liter engines
Caution! Due to insufficient space to remove the exhaust manifold on an engine installed in a vehicle, it is necessary to first remove the power unit.
1. Remove the power unit.
2. Remove the screw clamp securing the flexible portion of the EGR pipe to the manifold.
3. Unscrew the union nut and remove the oil feed pipe from the top of the turbocharger.
4. Remove the two bolts and disconnect the oil return line flange (A) from the turbocharger (B – suspension mounting bolt).
5. Remove the turbocharger mounting bolt.
6. Unscrew the manifold mounting nuts and remove the manifold with the turbocharger.
Installation
1. Installation is carried out in the reverse order of removal.
2. Please consider the following points:
- when installing, replace all gaskets;
- on 1.9 liter engines, install a turbocharger and exhaust manifold;
- on 2.1 liter engines, secure the EGR pipe with a special screw clamp;
- on 2.1 liter engines, install a power unit.