1. Disconnect the collar securing the air delivery sleeve to the turbocharger.2. Diconnect the vapour recovery pipe from the air delivery sleeve to the turbocharger.3. Disconnect the collar from turbocharger (3a) and remove the air delivery sleeve to turbocharger (3b).
Engines: 2.3 JTD 16V
1. Loosen the retaining bolts of the collar joining the intake pipe rigid section to the turbocharger.2. Unscrew nuts (2a) securing the pipe to the bracket on the cylinder head, and engine oil vapour pipe fitting retaining bolt (2b).3. Remove the rigid section of the air pipe from the turbocharger.
Engines: 2.3 JTD 16V
1. Undo the retaining bolts.2. Remove the engine oil vapour separator.
Engines: 2.3 JTD 16V
1. Disconnect the electrical connections:
Description
Connector
1a
Injector
N070A
Description
Connector
1a
Injector
N070B
Description
Connector
1a
Injector
N070C
Description
Connector
1a
Injector
N070D
Description
Connector
1b
Fuel pressure sensor
K083
Description
Connector
1c
Air pressure - temperature sensor
K044
Description
Connector
.
Heater plugs
A040A
Description
Connector
.
Heater plugs
A040B
Description
Connector
.
Heater plugs
A040C
Description
Connector
.
Heater plugs
A040D
Description
Connector
1d
Timing sensor
K047
Description
Connector
1e
Coolant temperature sending unit (for instrument panel)
K035
Description
Connector
1f
Engine coolant temperature sensor/sender unit
K036
Description
Connector
1g
Fuel pressure regulator
N077
Engines: 2.3 JTD 16V
1. Unscrew the fitting of the return pipe to the return manifold.2. Undo retaining bolt (1a), undo connector (1b) and disconnect delivery pipe (1c) from pump to fuel manifold.3. Undo the connectors for the supply pipes from the manifold to the injectors.4. Undo the bolts fixing the fuel manifold to the camshaft housing.5. Remove the fuel manifold complete with supply pipes to the injectors.
Engines: 2.3 JTD 16V
1. Press the fastening springs (1a) and disconnect the fuel recirculation pipe (1b) from the injectors.2. Undo the bolts fixing the brackets.3. Use the extractor and driver to remove the injectors from their seats on the cylinder head extension.
Description
Code
Function
.
Mallet
1.840.206.001
Injector removal
Description
Code
Function
.
Extractor
1.870.850.000
Injector removal
Engines: 2.3 JTD 16V
1. Undo the retaining bolts.2. Remove the cylinder head extension complete with camshafts.3. Remove the underlying gasket.
- Fit a new gasket to the cylinder head.- Fit the cylinder head extension complete with camshafts and camshaft timing tools.- Tighten the bolts securing the cylinder head extension to the cylinder head to torque.
Value - daNm
Fastening
Component
Ø
.
11,5
Bolt
CYLINDER HEAD EXTENSION
M12X1.25
Value - daNm
Fastening
Component
Ø
.
1
Bolt
CYLINDER HEAD EXTENSION
M6
Value - daNm
Fastening
Component
Ø
.
2.5
Bolt
CYLINDER HEAD EXTENSION
M8X1.25
- Lower the vehicle.- Fit the injectors in the seats in the camshaft housing.- Tighten the bolts fixing the brackets.
Value - daNm
Fastening
Component
Ø
.
2.5
Bolt
INJECTORS(DIESEL)
M8
- Fasten the recirculation pipe on the injectors using securing bands.- Fit the fuel manifold complete with supply pipes to the injectors.- Tighten the bolts fixing the fuel manifold to torque.
Value - daNm
Fastening
Component
Ø
.
2.5
Bolt
INJECTOR FUEL MANIFOLD (DIESEL)
M8
- Tighten the connectors for the pipes on the injectors to torque.
Value - daNm
Fastening
Component
Ø
.
2.3
Connectors
INJECTOR FUEL MANIFOLD PIPE
M12X1.5
- Tighten the connector for the fuel supply pipe from the pressure pump to torque.- Tighten the bolt fixing the fuel supply pipe from the pressure pump to the bracket.- Screw in the connector for the return pipe from the single fuel manifold to the return manifold and tighten it to torque.
Value - daNm
Fastening
Component
Ø
.
4
Connector
INJECTOR FUEL MANIFOLD (DIESEL)
M16
- Position the injection wiring and connect the electrical connections disconnected previously.
Description
Connector
Injector
N070A
Description
Connector
Injector
N070B
Description
Connector
Injector
N070C
Description
Connector
Injector
N070D
Description
Connector
Fuel pressure sensor
K083
Description
Connector
Air pressure - temperature sensor
K044
Description
Connector
.
Heater plugs
A040A
Description
Connector
.
Heater plugs
A040B
Description
Connector
.
Heater plugs
A040C
Description
Connector
.
Heater plugs
A040D
Description
Connector
Timing sensor
K047
Description
Connector
Coolant temperature sending unit (for instrument panel)
K035
Description
Connector
Engine coolant temperature sensor/sender unit
K036
Description
Connector
Fuel pressure regulator
N077
- Fit the rigid section of the air pipe from the turbocharger and tighten the bolt fixing the collar.- Tighten the bolts fixing it to the cylinder head.- Tighten the bolt fixing the engine oil vapour pipe.- Connect to the turbocharger and air cleaner case.- Connect the engine oil vapour separator pipe to the fitting.
