Remove
Detach engine compartment seal (2),
Remove water deflector cover (1),
Remove fastening bolts (3) and fastening nuts (4),
Remove bulkhead cover plate insulation (5),
For Y 20 DTH, Y 22 DTR engine:
- Release hose clamp (3) from charge air hose,
- Remove clamp (1) from charge air pipe,
- Remove fastening bolt (2) and remove charge air pipe – note gasket,
Remove fastening bolts (1) and (2) from wiring trough (3). Push wiring trough aside,
Remove centre heat shield for turbocharger,
Release fastening bolt for exhaust manifold support from exhaust manifold – do not remove,
Remove upper starter fastening bolt,
Detach lower engine compartment cover – see operation "Lower Engine Compartment Cover, Detach and Reattach" in group "A",
Remove fastening bolts (3), release fastening nut (2) and remove starter heat shield,
Detach wiring trough (4) and ground cable from cylinder block,
Disconnect cable connections (5) from starter. Detach starter cable ties,
Remove fastening bolt for starter bracket together with exhaust manifold support (1),
Remove lower starter fastening bolt and remove starter,
Note. Check starter – see operation "Starter, Check (Starter Installed)" or "Starter, Check (Starter Removed and Disassembled)" (X 16 XEL Engine) in group "J",
Disassemble and reassemble starter – see operation "Valeo Starter, Disassemble and Reassemble" (X 16 XEL Engine) in group "J",
Install
Insert starter, attach lower starter fastening bolt and hand-tighten,
Attach fastening bolt for starter bracket to cylinder block together with exhaust manifold support and hand-tighten,
Insert upper starter fastening bolt from above and tighten – tightening torque 45 Nm / 33 lbf. ft,
Secure exhaust manifold support to exhaust manifold – tightening torque 25 Nm / 18.5 lbf. ft,
Attach centre heat shield for turbocharger. Attach wiring trough to cylinder head cover and bracket,
Tighten lower starter fastening bolt – tightening torque 45 Nm / 33 lbf. ft,
Tighten fastening bolt for starter bracket together with exhaust manifold support – tightening torque 25 Nm / 18.5 lbf. ft,
Attach cable connections to starter. Attach new cable ties,
Attach ground cable and wiring trough to cylinder block. Attach starter heat shield,
Attach lower engine compartment cover – see operation "Lower Engine Compartment Cover, Detach and Reattach" in group "A",
For Y 20 DTH, Y 22 DTR engine: Install charge air pipe: Install charge air pipe - see "Illustration Air Duct, Y 20 DTH up to MY 2003" or illustration "Air Duct Y 20 DTH from MY 2003, Y 22 DTR".
Insert and attach bulkhead cover plate insulation. Attach water deflector cover. Attach engine compartment seal,