Exhaust Manifold: Service and Repair

1. Disconnect battery ground cable and drain cooling system.
2. Remove throttle body air intake tube.
3. Disconnect intercooler hose from turbocharger assembly and position out of the way.
4. Disconnect the Exhaust Gas Oxygen (EGO) sensor.
5. Remove bolts retaining lower heat shield to turbocharger and remove heat shield.
6. Remove bolts retaining upper and side heat shields, then the heat shields.
7. Remove power steering pump and bracket and position aside.
8. Disconnect lower radiator hose from water pump.
9. Remove screws retaining air cleaner duct tube, loosen tube and position duct tube aside.
10. Disconnect coolant return hose at turbocharger.
11. Remove bolt and brass sealing washers retaining the oil supply line at engine block.
12. Raise and support vehicle.
13. Disconnect front exhaust pipe from turbocharger.
14. Remove exhaust hangers and pull down and left on exhaust pipe.
15. Disconnect oil return hose at turbocharger.
16. Disconnect coolant return hose at turbocharger.
17. Remove turbocharger support bracket bolts.
18. Remove coolant bypass tube bolts from water pump.
19. Lower vehicle.
20. Loosen retaining clamp on coolant bypass tube at rear of cylinder head.
21. Remove 11 nuts from exhaust manifold.
22. Pull coolant bypass tube bracket from exhaust stud and position aside.
23. Pull exhaust manifold off stud and move assembly slightly to the righthand side of engine compartment to clear cooling fan. Remove turbocharger and exhaust manifold assembly from vehicle.
24. Working on bench, remove four nuts retaining turbocharger to exhaust manifold, separate assembly and discard gasket.
25. Reverse procedure to install. If turbocharger was replaced proceed as follows:
a. Disconnect ignition coil.
b. Crank engine for 20 seconds.
c. Connect ignition coil.
d. Start engine and run at idle for 30 seconds.
e. Check for leaks.