Gasket - inlet and exhaust manifold - ’l’ series (page 3 of 3)

21. Remove 6 bolts and 6 nuts securing inlet and exhaust manifold to cylinder head.
22. Release and remove manifolds and turbocharger assembly.
23. Remove and discard manifold gasket.

Refit

1. Clean mating faces of manifolds and cylinder head.
2. Fit NEW manifold gasket.
3. Clean mating faces of EGR recirculation pipe and plenum chamber.
4. Fit NEW gasket to plenum chamber.
5. Manoeuvre manifolds and turbocharger assembly into position and align to cylinder head.
6. Apply Loctite 270 to threads of manifold bolts.
7. Fit nuts, bolts and washers securing manifold to cylinder head. Working in the sequence illustrated tighten manifold nuts to 25 Nm.and manifold bolts to 33 Nm.
8. Fit 2 bolts securing exhaust manifold to mounting bracket.
9. Clean mating faces of oil drain pipe and turbocharger.
10. Fit new gasket to turbocharger oil drain pipe. Align pipe to turbocharger, fit bolts and tighten to 10 Nm.
11. Clean face of EGR recirculation pipe.
12. Fit 2 bolts securing EGR recirculation pipe to plenum chamber and tighten to 9 Nm.
13. Fit 2 bolts securing inlet manifold to plenum chamber and tighten to 9 Nm.
14. Clean face of EGR valve elbow.
15. Fit new gasket to EGR valve elbow.
16. Fit and tighten bolts EGR valve to elbow.
17. Connect vacuum pipe from EGR solenoid to EGR valve.
18. Connect multiplug to intake air temperature IAT sensor.
19. Fit new sealing washers to oil feed banjo bolt, connect oil feed pipe to turbocharger and tighten to 20 Nm.
20. Connect boost pressure sensing pipe to turbocharger and secure clip.
21. Connect air outlet hose to turbocharger and tighten clip screw.
22. Position air intake hose and connect to turbocharger, tighten clip to secure.
23. Connect MAF sensor multiplug.
24. Connect breather hose to camshaft cover and tighten clip.
25. Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Adjustments.
26. Fit exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS - ’L’ SERIES, Repairs.
27. Connect battery earth lead.