Exhaust Manifold: Service and Repair

1. Remove turbocharger assembly as outlined under Turbocharger.

Fig. 14 Exhaust Manifold Replacement:

Fig. 15 Exhaust Manifold Replacement:

2. Replace exhaust manifold in numbered sequence as shown, Fig. 14 and 15.
3. Install rear exhaust manifold nuts in the following order:

Fig. 16 Rear Exhaust Manifold Nut Installation:

a. Torque nuts marked A to 22 ft. lbs., Fig. 16.
b. Torque nuts marked B to 34-38 ft. lbs.
c. Back off nuts marked B until a torque of 7 ft. lbs. is reached.
d. Torque nuts marked B to 21-22 ft. lbs., Fig. 16.
e. Install cone disc spring with grooved side facing up, then the nut, cone disc spring and washer in direction shown.
4. With the exhaust manifold stay resting on exhaust manifold, fit it along manifold over studs.
5. Install front exhaust manifold nuts in the following order:

Fig. 17 Rear Exhaust Manifold Nut Installation:

a. Torque nuts marked C to 22 ft. lbs., Fig. 17.
b. Temporarily install turbocharger assembly.
c. Torque nut marked D to 22 ft. lbs.
d. Torque nuts marked E and F to 34-38 ft. lbs.
e. Back off nuts marked E and F until a torque of 7 ft. lbs. is reached.
f. Torque nuts marked E and F to 21-22 ft. lbs.
g. Install cone disc spring with grooved side facing up, then the nut, cone disc spring and washer in direction shown.