Exhaust Manifold: Service and Repair
Removal Procedures1. Disconnect the negative battery cables.
^ For the front battery, refer to Battery Cable Replacement (Battery Cable Negative) in Starting and Charging.
^ For the auxiliary battery, refer to Battery Cable Replacement (Battery Cable Aux. Negative) in Starting and Charging.
2. Remove the engine cover from the vehicle.
3. Remove the heat shield from the turbocharger.
4. Remove the engine oil level indicator and tube.
5. Remove the transmission oil level indicator tube.
6. Raise the vehicle and support with safety stands.
7. Remove the glow plugs from the cylinder head.
8. Remove the exhaust pipes from the exhaust manifold to the turbocharger. Refer to Turbocharger Replacement
9. Remove the exhaust manifolds from the cylinder head.
10. Inspect and clean the sealing surfaces on the cylinder head and the exhaust manifold.
Installation Procedures
1. Install the exhaust manifold to the cylinder head (right side shown).
2. Install the exhaust manifold bolts (right side shown).
Notice: Refer to Fastener Notice in Service Precautions.
^ Tighten the bolts to 35 Nm (26 ft. lbs.).
3. Install the exhaust pipe from the turbocharger to the exhaust manifold.
4. Install the glow plugs in the cylinder head.
5. Remove the safety stands and lower the vehicle. Refer to Vehicle Lifting and Jacking.
6. Install the transmission oil level indicator tube.
7. Install the engine oil level indicator and tube.
8. Install the heat shield to the turbocharger assembly.
9. Install the engine cover in the vehicle.
10. Connect the battery negative cables from the batteries.