Vehicle Set

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





6. Working from above the vehicle, remove the bolts which secure the front section of the left hand exhaust manifold to the cylinder head.





7. Working from below the vehicle, reposition the steering rack for access.
Remove the two bolts which secure the steering rack at the driver's side.
Loosen, but do not remove, the two bolts which secure the steering rack at the passenger side.
Reposition the steering rack for access.





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





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





10. Remove the bolts which secure the front section of the right hand exhaust manifold to the cylinder head.





11. 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.





12. Remove the manifold.
Remove the manifold and the manifold gasket from the cylinder head.
Remove the gasket from the EGR flange.
13. If installing a new manifold, remove the two studs from the EGR flange of the manifold, and transfer them to the new manifold.
14. Clean the manifold faces (if installing), the EGR pipe flange and the mating faces on the cylinder head.
15. Use a thread tap (M8 x 1,25 plug) to clean out the threads of each manifold securing bolt hole, in the cylinder heads.

Installation
1. Use new manifold securing bolts and install a spacer to each.





2. Install each 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 each manifold to 16-20 Nm.





5. Install the steering rack.
Reposition the steering rack.
Install and tighten the rack mounting bolts on the driver's side to 40-50 Nm.
Tighten the rack mounting bolts on the passenger side to 40-50 Nm.





6. From above the vehicle, connect the EGR pipe to the right hand 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, left hand side.
8. Install the downpipe catalytic converter, right hand side.
9. Install the front silencer.
10. Install the air cleaner assembly.
11. Remove paintwork protection sheets and close the engine compartment.