Exhaust Manifold: Service and Repair
EXHAUST MANIFOLDREMOVAL
1. Disconnect the negative battery cable.
2. Remove the exhaust heat shield.
3. Raise and support the vehicle.
4. Remove the turbocharger support bracket.
5. Loosen the exhaust pipe to engine bracket fasteners at the rear of the engine block.
6. Remove the exhaust hanger fasteners at the muffler.
7. Disconnect the front exhaust pipe to turbocharger fastener (Fig. 69).
8. Position the front exhaust pipe aside.
9. Lower the vehicle.
10. Remove the air cleaner housing hose from the turbocharger and position aside (Fig. 69).
11. Remove the turbocharger oil cooler lines (Fig. 70).
12. Remove the turbocharger to exhaust manifold fasteners and remove turbocharger (Fig. 70).
13. Remove the self locking exhaust manifold fasteners (Fig. 70).
14. Remove exhaust manifold and clean mating surface.
INSTALLATION
NOTE: Exhaust manifold surface must be flat within 0.006 inch per foot (0.15 mm per 300 mm) of manifold length.
1. Inspect exhaust manifold gasket surface for flatness with a straight edge.
2. Inspect exhaust manifold for cracks or distortion.
3. Install new exhaust manifold gasket over the studs.
4. Position the exhaust manifold over to studs and tighten retaining nuts to 30 Nm (22 ft. lbs.).
NOTE: Replace the turbocharger oil cooler line banjo bolt seals before installing the oil cooler line.
5. Install turbocharger.
6. Raise and support the vehicle.
7. Install the front exhaust pipe to turbocharger (Fig. 69).
8. Install the exhaust hanger fasteners at the muffler.
9. Tighten the exhaust hanger bracket to engine block.
10. Install the turbocharger support bracket.
11. Lower the vehicle.
12. Install the air cleaner duct to the turbocharger (Fig. 69).
13. Install the exhaust heat shield.
14. Connect the negative battery cable.