Gasket - exhaust manifold

Gasket - exhaust manifold

$% 30.15.12.01

Disassembly

Note: The following procedure covers engines fitted with or without an EGR cooler. The EGR cooler is bolted to the front of the cylinder head.

EU3 engine illustrated

1. Remove 3 bolts securing heater pipe to cylinder head and turbocharger heat shield.
2. Remove heater pipe.
3. Remove bolt and remove turbocharger heat shield.
4. Remove and discard 2 Allen screws securing EGR pipe to exhaust manifold.
5. Remove banjo bolt securing oil feed pipe to turbocharger and discard sealing washers.
6. Loosen turbocharger drain hose union at cylinder block.
7. Remove 10 nuts and remove exhaust manifold and turbocharger.
8. Remove manifold gasket.

Reassembly

1. Clean exhaust manifold mating faces.
2. Position exhaust manifold to cylinder head using new gasket and fit manifold nuts. Working from the centre outwards, fit and tighten nuts to 25 Nm (18 lbf.ft).
3. Clean turbocharger drain and feed hose unions.
4. Fit turbocharger oil drain hose to cylinder block and tighten union to 48 Nm (35 lbf.ft) .
5. Fit new sealing washers to turbocharger oil feed pipe, fit banjo bolt and tighten to 25 Nm (18 lbf.ft).
6. Position EGR pipe to exhaust manifold. Fit new Allen screws and tighten to 10 Nm (7 lbf.ft).
7. Position turbocharger heat shield.
8. Position heater pipe to cylinder head and tighten bolts to 25 Nm (18 lbf.ft).
9. Position exhaust manifold heatshield and tighten M6 bolts to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).