Remove
- 1. Disconnect battery negative lead
- 2. Remove engine cover insulation • Remove 3x cap (1), 3x bolt
- 3. Disconnect air intake ducting from air cleaner housing (1) • Release 2x clip
- 4. Disconnect harness connector (1) from mass air flow meter, then release harness (2) from air cleaner housing
- 5. Disconnect air intake hose for turbocharger from mass air flow meter • Release clip (1)
- 6. Release harness and fuel lines from 2x clip of air cleaner housing
- 7. Remove air cleaner housing from 2x support bracket • Remove front nut, washer (1) • Remove rear nut, washer (2)
- 8. For vehicles up to MY2006, disconnect air intake hose from intake manifold, then move to side • Release clamp (1)
- 9. For vehicles as of MY2007, remove pipe (1) from intercooler and intake manifold • Release 2x clip
- 10. Disconnect hose for charge pressure sensor from intake manifold • Release clamp (1)
- 11. Disconnect harness connector (1) from exhaust gas recirculation valve
- 12. Remove breather pipe (1) from air intake hose and engine oil separator (2) • Release 2x clip (3)
- 13. Raise vehicle
- 14. Remove engine and transmission undershield from vehicle
- 15. Remove right splash shield • Release wash hose (if installed) from support clip (1) • Remove 2x bolt (2) • Remove screw (3)
- 16. Disconnect front silencer from catalytic converter • Remove 2x nut (1)
- 17. Remove front silencer from intermediate pipe • Remove clamp (2)
- 18. Remove heat shield (1) from subframe • Remove 2x bolt
- 19. Disconnect negative lead from support bracket for catalytic converter • Remove nut (1)
- 20. Remove support bracket (1) from transmission, starter and catalytic converter • Remove 3x bolt, nut
- 21. Remove support bracket (1) from engine and catalytic converter • Remove nut (1), bolt (2)
- 22. Remove catalytic converter (1) from turbocharger • Remove 4x nut (2), gasket
- 23. Disconnect hose (1) from turbocharger, then remove from engine compartment • Release clamp (2)
- 24. Disconnect hose (3) from turbocharger • Release clamp (4)
- 25. Release support bracket for oil feed pipe from intake manifold • Remove bolt (1)
- 26. Disconnect oil feed pipe from turbocharger • Release union nut (1) – Discard O ring
- 27. Remove oil supply pipe from cylinder block • Release union nut (1) – Discard O ring
- 28. Disconnect oil return pipe from turbocharger • Remove 2x bolt (1), gasket
- 29. Disconnect vacuum hose (1) from wastegate vacuum actuator, then move to side
- 30. Remove turbocharger (1) from exhaust manifold • Remove 3x nut (2) – Discard gasket
- 31. Remove engine lifting eye (1) from exhaust manifold • Remove 2x bolt (2)
- 32. Disconnect pipe for exhaust gas recirculation (EGR) from exhaust manifold • Release clamp (1)
- 33. Remove exhaust manifold (1) from cylinder head • Remove 9x nut, gasket
- 34. Remove intake manifold (1) and gasket from cylinder head
Install
Important. Locking compound must be applied to the manifold stud on installation to the cylinder head to prevent coolant loss – see “Sealants, Lubricants and Locking Compounds”
- 35. Install new gasket and intake manifold (1) to cylinder head
Important. Locking compound must be applied to the manifold stud on installation to the cylinder head to prevent coolant loss – see “Sealants, Lubricants and Locking Compounds”
- 36. Install new exhaust manifold (1) to cylinder head • Clean mating surfaces • Install new gasket, 9x new nut 28 Nm symmetrically
- 37. Install engine lifting eye (1) to exhaust manifold • Install 2x bolt (2) 20 Nm
- 38. Connect pipe for EGR valve to exhaust manifold • Secure clamp (1)
- 39. Install turbocharger (1) to exhaust manifold • Use new gasket • Install 3x nut (2) 26 Nm
- 40. Connect vacuum hose (1) to wastegate vacuum actuator
- 41. Install oil feed pipe to cylinder block • Use new O ring • Secure union nut (1) 22 Nm
- 42. Install oil feed pipe to turbocharger • Use new O ring • Secure union nut (1) 22 Nm
- 43. Secure support bracket for oil supply pipe to intake manifold • Install bolt (1)
- 44. Connect oil return pipe to turbocharger • Use new gasket • Install 2x bolt (1) 12 Nm
- 45. Connect hose (3) to turbocharger • Secure clamp (4) • Install hose (1) to engine compartment, then connect to turbocharger • Secure clamp (2)
- 46. Install catalytic converter (1) to turbocharger • Use new gasket • Secure 4x nut (2) 24 Nm
- 47. Install support bracket (1) to engine and catalytic converter • Install nut (1) 30 Nm , bolt (2) 44 Nm
- 48. Install support bracket (1) to transmission, starter, and catalytic converter • Install 3x bolt 21 Nm , nut 21 Nm
- 49. Connect negative lead to support bracket for catalytic converter • Install nut (1) 21 Nm
- 50. Install heat shield (1) to subframe • Install 2x bolt 8 Nm
- 51. Connect front silencer to catalytic converter • Use new gasket • Install 2x nut (1)
- 52. Install front silencer to intermediate pipe • Install clamp (2)
- 53. Install right splash shield • Install 2x bolt (2) 8 Nm • Install screw (3) • Secure wash hose to support clip (1)
- 54. Install engine and transmission undershield to vehicle
- 55. Lower vehicle
- 56. Install breather pipe (1) to air intake hose and engine oil separator (2) • Secure 2x clip (3)
- 57. Connect harness connector (1) to exhaust gas recirculation valve
- 58. Connect hose for charge pressure sensor to intake manifold • Secure clamp (1)
- 59. For vehicles up to MY2006, connect air intake hose to intake manifold • Secure clamp (1)
- 60. For vehicles as of MY2007, install pipe (1) to intercooler and intake manifold • Secure 2x clip
- 61. Install air cleaner housing to 2x support bracket • Install front nut, washer (1) 8 Nm • Install rear nut, washer (2) 8 Nm
- 62. Secure harness and fuel lines to 2x clip of air cleaner housing
- 63. Connect air intake hose for turbocharger to mass air flow meter • Secure clamp (1)
- 64. Connect harness connector (1) to mass air flow meter, then secure harness (2) to air cleaner housing
- 65. Connect air intake ducting to air cleaner housing (1) • Secure 2x clip
- 66. Install engine cover insulation • Install 3x bolt, 3x cap (1)
- 67. Connect battery negative lead
- 68. Remove engine immobiliser/instrument panel fuse from interior fuse box • Remove left ashtray housing from instrument panel – Release 4x clip • For vehicles up to MY2006, remove fuse (2) • For vehicles from MY2007, remove fuse (1)
- 69. Crank engine for five seconds
- 70. Install engine immobiliser/instrument panel fuse to interior fuse box
- 71. Install left ashtray housing to instrument panel • Secure 4x clip
- 72. Program all volatile memories