B1HG29K1 - 406D9 DW10TD ENGINE DW10ATED ENGINE

REMOVAL - REFITTING TURBOCHARGER

1 - SPECIAL TOOLS

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[1] Connecting rod unclipping tool (-).0317-AC .

ALL MODELS

2 - REMOVAL

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Remove the shields under the power train .

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IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand the torsion, traction or bending tensions caused by the removal of one of the power train supports .

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Remove : The turbo pipe (1) .

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Remove :

• the torque reaction link (2)
• the bolt (3) (turbo pipe fastener)

Unscrew the collar (4) .

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Move aside : The power steering pipes (5) .

Uncouple the gearbox control rods (Using the tool [1]) .

Move aside the gearbox control rods .

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Remove :

• the style cover (6)
• the air cleaner assembly (7)

Move aside the EGR solenoid valve assembly (8) .

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Remove : The bolt (9) .

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Move aside the inlet duct (10) .

Remove the hose (11) .

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Remove the air conduit (10) (From above the vehicle) .

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Remove the air conduit (12) (From below the vehicle) .

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Plug the turbo inlet and outlet openings .

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Remove : The supports (13), (14) .

Move aside : The oil unions (15), (16) .

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Disconnect the pipe (17) .

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Slacken the nuts (18) .

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Remove : The nuts (19) .

Retrieve the spacers .

Move aside : The assembly (20), (21) .

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Remove :

• the nuts (18)
• the turbocharger (21)

ALL MODELS

3 - REFITTING

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Check that no foreign bodies are present (In the induction system) .

Always replace the turbocharger securing nuts and the seals .

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Tighten : The studs on the manifold to 1 daN.m .

Fit :

• the turbocharger (21)
• the nuts (18)

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Fit :

• the spacers
• the nuts (19)

Tighten : The nuts (19) to 2.5 da.Nm .

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Tighten : The nuts (18) to 2.5 da.Nm .

Tighten the union (15) to 2.2 da.Nm .

Position : The pipe (16) .

Fit : The supports (13), (14) .

Tighten the bolts by hand .

Tighten :

• the bolts (22) to 2.3 da.Nm
• the nut (23) to 3 da.Nm
• the bolt (24) to 3 da.Nm
• the nut (25) to 3 da.Nm

Continue the fitting operations in the reverse order to removal .

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Refit the union (11) fitted with a new seal .

Fit :

• the nuts (26)
• the bolts (27)

Tightening torque(s) :

• the nut (26) to 2.25 da.Nm
• the bolts (27) to 0.8 da.Nm

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Continue the fitting operations in the reverse order to removal .

Refit the torque reaction link (2) .

Tighten :

• the bolt (28) to 5 da.Nm
• the bolt (29) to 6 da.Nm
• the wheel bolts to 9 da.Nm

IMPERATIVE : always renew : the exhaust clip .

Fit : The exhaust pipe .

Fill the gearbox .