Exhaust manifold gasket - ’t’ series with air conditioning

Do not carry out further dismantling if component is removed for access only.

12. Remove heated oxygen sensor from exhaust manifold and collect sealing washer.
13. Fit sealing washer to sensor.
14. Fit sensor to NEW manifold and tighten to 55 Nm.

Refit

1. Clean dipstick tube and housing.
2. Clean exhaust manifold and cylinder head mating faces.
3. Fit NEW gasket to cylinder head.
4. Fit manifold and position to cylinder head studs.
5. Fit 2 nuts securing manifold to cylinder head, but do not tighten.
6. Clean dipstick tube and apply Loctite 601.
7. Fit dipstick tube to engine.
8. Fit bolt securing dipstick tube to coolant rail.
9. Fit dipstick.
10. Fit and tighten bolt securing PAS pipe to coolant rail.
11. Fit bolt securing coolant rail to cylinder head and tighten to 25 Nm .

12. Align coolant rail support bracket to manifold fixing, fit nuts and bolts and tighten manifold fixings in sequence shown to 45 Nm.
13. Connect heated oxygen sensor multiplug and secure to clip.
14. Clean exhaust front pipe to manifold mating faces.
15. Fit NEW exhaust front pipe flange gasket to manifold, connect front pipe, fit nuts and tighten to 50 Nm.
16. Connect battery earth lead.

EXHAUST MANIFOLD GASKET - ’T’ SERIES WITH AIR CONDITIONING

Service repair no - 30.15.12/20

Remove

1. Remove radiator cooling fan. See COOLING SYSTEM, Repairs.
2. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
3. Remove alternator. See ELECTRICAL, Repairs.
4. Remove 4 nuts securing exhaust front pipe to manifold.
5. Release front pipe from manifold studs.
6. Remove and discard front pipe to manifold flange gasket.
7. Position container beneath power steering pump.

8. Using a 22 mm crow foot spanner, remove banjo bolt securing high pressure pipe to steering pump, allow PAS fluid to drain.
9. Collect 2 banjo sealing washers and discard.

CAUTION: Plug the connections.