Removal procedure
1. Disconnect the negative battery cable.
2. Remove the decorative cover. See «Decorative cover» in this section.
3. Remove the hoses and air ducts of the charge air system. See «Air injection system» in this section.
4. Disconnect the lower radiator hose and drain the coolant. See Section 1D1, "Engine Cooling - 2.0 Diesel".
5. Remove the accessory belt. See «Accessory drive belt and tensioner» in this section.
6. Remove the fuel line to the injection pump from the fuel injection pump.
7. Remove the fasteners of the power steering pump and move to the left side.
8. Remove the coolant hose from the intake manifold.
9. Remove the upper radiator hose.
10. Remove the injection pump return hose.
11. Remove the oil level indicator tube.
12. Remove the fuel line to the common rail located between the common rail and the fuel injection pump. See Section 1F1, Engine Controls - 2.0 Diesel.
13. To turn away a coupling bolt of a terminal block of wires from an inlet collector.
14. Loosen the locking bolts of the glow plug fuse box.
15. Remove engine wiring.
- Disconnect the common rail pressure sensor connector.
- Disconnect the CTS connector.
- Disconnect injection pump connector.
- Disconnect the generator connector.
- Disconnect the A/C compressor connector.
- Disconnect the starter solenoid wire connector.
- Disconnect the cooling fan connectors.
- Disconnect the T-MAP sensor connector.
- Disconnect the camshaft position sensor connector
- Disconnect the ETC housing connector.
- Disconnect the common rail regulator connector.
16. Remove the engine wiring harness guide.
17. Remove the coolant bypass hose.
18. Remove the exhaust pipe from the EGR cooler.
19. Remove the intake manifold with gasket.
Installation procedure
1. Install the exhaust manifold with a new gasket.
2. Install the EGR cooler outlet pipe.
Tighten
Tighten intake manifold bolts and nuts to 23 Nm (17 lb-ft).
Tighten the bolts and nuts of the exhaust pipe of the exhaust gas recirculation cooler to 20 Nm (14.8 lb-ft).
3. Install engine wiring.
4. Tighten the retaining bolts of the glow plug fuse box.
5. Screw the coupling bolt of the engine wiring connector on the intake manifold.
6. Install the fuel line to the common fuel rail located between the common fuel rail and the fuel injection pump. See Section 1F1, Engine Controls - 2.0 Diesel.
7. Install the oil level indicator tube.
8. Install the power steering pump.
9. Install the fuel line to the injection pump on the fuel injection pump.
Tighten
Tighten the glow plug fuse box bolts to 10 Nm (88.5 lb-in).
Tighten the pinch bolt of the engine wiring harness terminal block to 15 Nm (11.1 lb-ft).
Tighten the nut securing the fuel line to the common fuel rail to 20 Nm (14.8 lb-ft).
Tighten the bolt securing the fuel line to the common fuel rail to 10 Nm (88.5 lb-in).
Tighten the oil level indicator tube bolts to 11 Nm (97.4 lb-in).
Tighten the steering pump bolts to 25 Nm (18.4 lb-ft).
Tighten the bolt securing the fuel line to the injection pump (to intake manifold) up to 9 Nm (79.7 lb-in).
Tighten the bolt securing the fuel line to the injection pump to 25 Nm (18.4 lb-ft).
