Inlet and exhaust manifold gasket - ’l’ series (page 3 of 3)

Refit

1. Clean mating faces of manifold and cylinder head.
2. Fit new manifold gasket to cylinder head.
3. Clean mating faces of exhaust manifold and exhaust front pipe.
4. Fit manifold flange gasket.
5. Manoeuvre inlet and exhaust manifold assembly into position and align to cylinder head.
6. Fit nuts, bolts and washers securing manifold to cylinder head.

7. Working in the sequence illustrated tighten manifold nuts to 25 Nm and bolts to 25 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. Align exhaust front pipe to exhaust manifold. Fit 3 nuts and tighten to 45 Nm.
12. Clean mating faces of EGR valve, inlet manifold and exhaust manifold.
13. Fit new gaskets to EGR valve and recirculation pipe.
14. Align EGR valve and recirculation pipe to inlet and exhaust manifolds.
15. Fit 2 bolts securing EGR valve recirculation pipe to exhaust manifold and tighten to 9 Nm.
16. Fit 2 Allen bolts securing EGR valve to inlet manifold and tighten to 25 Nm.
17. Connect vacuum pipe from EGR solenoid to EGR valve.
18. Connect vacuum hose to turbocharger actuator.
19. Fit NEW sealing washers to oil feed pipe, banjo bolt.
20. Connect oil feed pipe to turbocharger and tighten banjo bolt to 20 Nm.
21. Connect air intake hose to turbocharger, tighten clip.
22. Connect breather hose to camshaft cover and tighten clip.
23. Fit turbocharger outlet pipe. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs.
24. Fit engine acoustic cover. See BODY, Exterior fittings.
25. Fit underbelly panel. See BODY, Exterior fittings.
26. Connect battery earth lead.