Exhaust System: Service and Repair

EXHAUST MANIFOLD





COMPONENTS

REMOVAL





1. Remove the heat protector.
2. Remove the EGR pipe (RH manifold).





3. Remove the exhaust manifold.
4. Remove the exhaust manifold gasket.

INSPECTION
1. Check for damage or cracks.





2. Using a straight edge and feeler gauge, check for distortion on the cylinder head matching surface.
Standard value: 0.15 mm (0.006 inch) or less
Service limit: 0.3 mm (0.012 inch) or less
3. Check the exhaust manifold for damage and cracks.

INSTALLATION





1. Install the exhaust manifold with gasket.
Tightening torque
Exhaust manifold: 39.2 - 49.0 Nm (4.0 - 5.0 kg-m, 28.9 - 36.2 ft. lbs.)

NOTE: Do not re - use an exhaust manifold gasket.

2. Install the EGR pipe.
Tightening torque: 49.0 - 68.6 Nm (5 - 7 kg-m, 36.2 - 50.6 ft. lbs.)





3. Install the heat protector.
Tightening torque: 11.8 - 14.7 Nm (1.2 - 1.5 kg-m, 8.7 - 10.8 ft. lbs.)