Table of contents: Cars with diesel engine DK5ATE 🠇 Cars with petrol engine XU10J2TE 🠇
Cars with diesel engine DK5ATE
Removal
1. Jack up the car and place it on jack stands.
2. Remove the engine compartment splash guard.
3. Drain the transmission oil
4. Remove the right drive shaft.
5. Remove the intake pipe 1 (see illustration).
4.5 Remove the exhaust pipe 1
6. Disconnect the supply and return pipes 2 and 3 from the turbocharger (see illustration).
4.6 Disconnect the supply and return pipes 2 and 3 from the turbo compressor
7. Remove the heat reflector shield 4 (see illustration).
4.7 Remove the heat shield 4
8. Disconnect the outlet pipe 5 from the turbocharger (see illustration 4.7). Tightening torque: 20 Nm.
9. Remove bracket 6 (see illustration 4.7). The tightening torque of the bracket mounting bolts is 20 Nm.
10. Disconnect the oil return line7 from the cylinder block (see illustration 4.7).
11. Disconnect hose 8 from the turbocharger, unscrew nuts 9 and remove the turbocharger (see illustration). The tightening torque for the turbocharger mounting nuts is 25 Nm.
4.11 Disconnect hose 8 from the turbocharger, unscrew nuts 9 and remove the turbocharger
The turbocharger is installed in the reverse order of removal.
Attention. The fastening nuts and clamps, as well as the oil seals and gaskets of the oil lines, must be replaced after each dismantling.
Cars with petrol engine XU10J2TE
Removal
12. Jack up the car and place it on jack stands.
13. Remove the connecting bracket 1 (see illustration).
4.13 Remove the connecting bracket 1
14. Remove the exhaust pipe mounting clamp.
15. Disconnect the return oil line 2 (see illustration).
4.15 Disconnect the return oil line 2
16. Unscrew the lower bolt 3 securing the exhaust manifold heat shield (see illustration 4.15). The tightening torque of the bolt is 15 Nm.
17. Clamp hose 4 with a suitable clamp, such as clamp "a", and disconnect the hose (see illustration).
4.17 Clamp hose 4 with a suitable clamp, such as clamp "a", and disconnect the hose. The tightening torque of the hose fastening nut is 30 Nm
18. Move the power steering pump reservoir away from the work area.
19. Remove the electromagnetic valve 5 of the EGR system, and then disconnect the pipe 6 from the turbocharger (see illustration).
4.19 Remove the electromagnetic valve 5 of the EGR system, and then disconnect the pipe 6 from the turbocharger
20. Remove the exhaust manifold 7 together with the sealing gasket (see illustration).
[Original publication on the website PeugeotBook.ru]
4.20 Remove the exhaust manifold together with the sealing gasket
21. Plug the turbocharger inlet and outlet ports with suitable plugs.
22. Clamp the hose 8 with a suitable clamp, for example, clamp "a", and unscrew the nut 9 of its fastening (see illustration). Hose 8 seals must be replaced after each dismantling.
4.22 Clamp the hose with a suitable clamp, for example clamp "a", and unscrew the nut 9 of its fastening. The tightening torque of the nut is 30 Nm
23. Remove the exhaust manifold heat shield (see illustration).
4.23 Remove the exhaust manifold heat shield
24. Unscrew the two upper turbocharger mounting nuts.
25. Unscrew bolt 10 of the engine mount support (see illustration).
4.25 Unscrew bolt 10 of the engine mount support. Tightening torque - 50 Nm
26. Move the power unit forward approximately 40 mm by inserting a wooden block between the differential and the subframe.
27. Unscrew the mounting bolts and remove the supports 11 (see illustration).
4.27 Unscrew the mounting bolts and remove the supports 11
28. Unscrew the two lower turbocharger mounting nuts and carefully remove the turbocharger (see illustration).
4.28 Carefully remove the turbocharger
29. Replace sealing ring 12 (see illustration). Before installation, lubricate the new ring with LUBRITHERM G 200 grease.
The turbocharger is installed in the reverse order of removal, taking into account the following:
30. Turbocharger mounting nuts must be replaced after each dismantling. Their tightening torque is 40 Nm.
4.29 Replace sealing ring 12
31. Tighten bolts 13 and 14 for fastening supports 11 first by hand, and then with a force of 40 Nm (see illustration). First tighten bolts 13, then bolts 14.
4.31 Tighten bolts 13 and 14 securing supports 11 first by hand and then with a force of 40 Nm