Exhaust Manifold: Service and Repair

REMOVAL

1. Disconnect battery ground cable.
2. Loosen cap on coolant expansion tank and drain coolant from radiator.
3. Remove heater return hose at water pump.
4. Remove screw attaching coolant pipe routing bracket to right front side of valve cover.
5. Disconnect coolant pipe to expansion tank hose at coolant pipe.
6. Disconnect turbocharger oil supply line at turbocharger.
7. Disconnect turbocharger coolant supply and return tube at the turbocharger.
8. Disconnect PCV tube at turbo air inlet adapter.
9. Remove turbo to exhaust manifold attaching nuts.
10. Remove turbo support bracket.
11. Remove exhaust manifold to cylinder head attaching bolts, then the exhaust manifold.

Fig. 8 Installing exhaust manifold:

INSTALLATION

1. Ensure that exhaust manifold and the manifold surfaces on the cylinder head are clean.
2. Install exhaust manifold to cylinder head bolts. Torque bolts in two steps following proper torque sequence, Fig. 8. First, torque to 177-204 inch lbs., then to 20-30 ft. lbs.
3. Install turbocharger support bracket and the turbo to exhaust manifold nuts.
4. Connect PCV tube at turbo air inlet adapter.
5. Connect turbo coolant and oil supply lines at turbocharger.
6. Install heater pipe to coolant expansion tank hose at heater pipe.
7. Install coolant pipe retaining clip screw at valve cover.
8. Install coolant hose at water pump and refill cooling system.