Exhaust manifold - ’l’ series without intercooler (page 3 of 3)

22. Loosen the 6 bolts and 6 nuts securing inlet manifold and the exhaust manifold to cylinder head.
23. Remove 6 bolts securing exhaust manifold to cylinder head, collect 4 washers.
24. Remove 4 nuts securing exhaust manifold to cylinder head.
25. Release and remove exhaust manifold and turbocharger assembly. Do not carry out further dismantling if component is removed for access only.

26. Remove 3 nuts securing turbocharger to exhaust manifold.
27. Remove exhaust manifold.
28. Clean mating faces of turbocharger and exhaust manifold.
29. Fit turbocharger to exhaust manifold, fit nuts and tighten 25 Nm.

Refit

1. Replace inlet and exhaust manifold gasket. See this section.
2. Clean mating faces of exhaust manifold and cylinder head.
3. Clean mating faces of exhaust manifold and exhaust front pipe.
4. Manouvre exhaust manifold and turbocharger assembly in position on cylinder head.

5. Fit nuts, bolts and washers securing exhaust manifold to cylinder head. Working in the sequence illustrated, tighten exhaust manifold nuts to 25 Nmand the bolts to 33 Nm.
6. Fit bolts securing exhaust manifold to mounting bracket and tighten to 25 Nm.
7. Clean mating faces of oil drain pipe and turbocharger.
8. Fit new gasket to turbocharger oil drain pipe. Align pipe to turbocharger, fit bolts and tighten to 10 Nm.
9. Connect exhaust front pipe to manifold. See this section.
10. Clean mating faces of EGR valve, inlet manifold and exhaust manifold.
11. Fit new gasket to EGR valve. Align EGR valve to inlet manifold and exhaust manifold.
12. Fit Allen bolts securing EGR valve to exhaust manifold and tighten to 25 Nm.