Right Hand

Removal
1. Open the engine compartment and fit paintwork protection sheets.
2. Remove the air cleaner assembly.
3. Remove the front silencer.
4. Remove the downpipe catalytic converter, right hand side.





5. From above the vehicle, disconnect the EGR pipe from the exhaust manifold.
Remove the two nuts which secure the EGR flange to the right hand exhaust manifold.
Reposition the EGR pipe from the manifold.





6. Remove the bolts which secure the front section of the exhaust manifold to the cylinder head.





7. If working on a right hand drive vehicle; reposition the steering rack for access.
Remove the two bolts which secure the steering rack at the passenger side.
Loosen, but do not remove, the two bolts which secure the steering rack at the driver's side.
Reposition the steering rack for access.





8. Working from below the vehicle, remove the manifold bolts.
Remove the bolts which secure the rear section of the exhaust manifold to the cylinder head.





9. Remove the manifold.
Remove the manifold and the manifold gasket from the cylinder head.
Remove the gasket from the EGR flange.
10. If installing a new manifold, remove the two studs from the EGR flange of the manifold, and transfer them to the new manifold.
11. Clean the manifold faces (if installing) and the mating faces on the cylinder head.
12. Use a thread tap (plug) to clean out the threads of the manifold securing bolt holes, in the cylinder head.

Installation
1. Install a spacer to each new manifold securing bolt (8 bolts).





2. Install the manifold and manifold gasket.
Install and align the new gasket to the cylinder head.
Install and align the manifold to the cylinder head.
Install the rear four bolts which secure the manifold, but do not tighten.
3. Working from above the vehicle, install and tighten the remaining manifold securing bolts to 16-20 Nm.
4. Working from below the vehicle, fully tighten the rear bolts on the manifold to 16-20 Nm.





5. Install the steering rack (if removed for access).
Reposition the steering rack.
Install and tighten the rack mounting bolts on the passenger side to 40-50 Nm.
Tighten the rack mounting bolts on the driver's side to 40 -5 0 Nm.





6. From above the vehicle, connect the EGR pipe to the exhaust manifold.
Install a new EGR gasket to the manifold.
Reposition the EGR pipe to the manifold.
Install the two nuts which secure the EGR flange to the exhaust manifold. Tighten to 18-24 Nm.
7. Install the downpipe catalytic converter, right hand side.
8. Install the front silencer.
9. Install the air cleaner assembly.
10. Remove paintwork protection sheets and close the engine compartment.