Page 857 of 3229
23. CAUTION: Make s ure t hat a new bolt is
i ns t alled.
Remove t he cranks haft damper. 23.
Remove t he rel uct or ring. 24.
Refer t o: Timi ng Cover (303-01B Engi ne - TD4 2.2L Dies el , Removal
and Inst all at ion).
25.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
26.
Page 858 of 3229
Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Exhaust Manifold
Removal and Inst all ati on
Removal
W ARNING: Observe due care when worki ng near a hot exhaust s ys tem.
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he exhaus t gas recirculat ion (EGR) cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi neEmi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
2.
Remove t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculateFil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removaland Inst all at ion).
3.
4. NOTE: Make s ure t hat al l openings are s eal ed.4.
5.
Page 859 of 3229
6. CAUTIONS:
Make s ure that t he area around the component i sclean and free of foreign materi al.
Make s ure that all openings are sealed. Us e newblanking caps.
6.
7.
8. CAUTION: Make s ure that all openi ngs ares ealed. Use new blanking caps.
Releas e t he turbocharger.
8.
Page 860 of 3229
Remove t he EGR cool er to exhaust mani fol d elbow.
9. 10. CAUTION: Make s ure t hat all openi ngs are
s ealed. Use new blanking caps.
• NOTE: Di scard the gas ket .
10.
Installation 1. CAUTION: Make s ure that the area around t he
component i s cl ean and free of foreign mat eri al .
Inst all a new gas ket. Inst all t he exhaus t manifol d.
Evenl y and progres s ively, t ighten t he bolt s i n
t he s equence s hown.
T orque: 25 Nm 1.
Inst all t he EGR cool er to exhaust mani fol d elbow.
T orque: 10 Nm 2.
3. CAUTIONS: Make s ure that new bolt s are ins t al led.
Ext reme cl eanli ness must be exerci sed when handli ng t hi s
component . Carbon depos it s mus t be careful ly removed from both faces of
t he turbocharger and exhaus t manifold prior to ass embly.
Inst all t he turbocharger.
3.
Page 861 of 3229
T orque:
24 Nm
Inst all t he turbocharger s upport bracket , but do not fully
t ighten at t his st age. Tight en the support bracket to turbocharger bol t.
T orque: 24 Nm Tight en the support bracket to cyli nder bl ock bolt s .
T orque: 24 Nm 4.
5. CAUTIONS: Make s ure that t he area around the component i s clean and
free of foreign mat eri al. Make s ure that new s eali ng washers are ins tall ed.
Connect t he turbocharger oil feed line.
T orque: 24 Nm 5.
Inst all t he turbocharger outl et pi pe.
T orque: 25 Nm 6.
Inst all t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculate Fil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removal
and Inst all at ion).
7.
Inst all t he EGR cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi ne
Emi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
8.
Check and top-up the engine oi l.
9.
Page 862 of 3229

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Cylinder Head
Removal and Inst all ati on
Removal
• NOTE: The valve cover and cylinder head is machined as an ass embly and cannot be serviced s eparately.
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he exhaus t manifol d.
Refer t o: Exhaus t Mani fol d (303-01B Engi ne - TD4 2.2L Di esel ,Removal and Ins tall ati on).
3.
Remove t he camshaft s .
Refer t o: Camshafts (303-01B Engine - TD4 2.2L Dies el, Removaland Inst all at ion).
4.
Remove t he thermost at.
Refer t o: Thermos tat (303-03B Engi ne Cool ing - TD4 2.2L Di es el,Removal and Ins tall ati on).
5.
Remove t he RH engine mount .
Refer t o: Engi ne Mount RH (303-01B Engi ne - TD4 2.2L Di esel ,Removal and Ins tall ati on).
6.
7.
Page 863 of 3229
Page 864 of 3229
11. CAUTION: Note the fit t ed pos i ti on of thecomponent pri or to removal.11.
12. W ARNING: Thi s s tep requi res t he aid ofanother technician.
Di scard the bolt s .
12.