Exhaust Manifold: Service and Repair

Exhaust Manifold

To Remove





1. Remove the heat shield over the exhaust manifold.
2. Remove the turbocharger.
3. Relieve the belt tensioner of load using an extension bar and insert a 6 mm drill bit in the hole, see illustration. Exercise great care to avoid breaking the belt tensioner at its end position. Remove the belt from the power steering pump pulley.
4. Remove the power steering pump bracket with pump and bend it aside.





5. Undo the exhaust manifold's nuts. Note that only the outer studs have sleeves.
6. Remove the exhaust manifold with gasket.


To Fit





1. Clean the surfaces and fit the exhaust manifold with a new gasket. Note that only the outer studs have sleeves.
Tightening torque: 25 Nm (18.5 ft. lbs.)





2. Mount the power steering pump bracket with pump and fit the belt on the pulley.
3. Relieve the belt tensioner of load using an extension bar and remove the drill bit.
4. Fit the turbocharger.
5. Fit the heat shield over the exhaust manifold.