Exhaust manifold (page 4 of 4)

Refit

1. Clean mating faces of exhaust manifold and cylinder head.
2. Clean mating faces of exhaust manifold and exhaust front pipe.
3. Fit inlet manifold. See this section.
4. Manoeuvre exhaust manifold and turbo-charger assembly into position and align to cylinder head.

5. Fit nuts, bolts and washers securing exhaust manifold to cylinder head. Working in the sequence illustrated tighten exhaust manifold nuts and bolts to 25 Nm.
6. Raise front of vehicle.

WARNING: Support on safety stands.

7. Fit and tighten bolt securing exhaust manifold to mounting bracket.
8. Clean mating faces of oil drain pipe and turbocharger.
9. Fit new gasket to turbocharger oil drain pipe. Align pipe to turbocharger, fit bolts and tighten to 8 Nm.
10. Fit new exhaust manifold flange gasket.
11. Align exhaust front pipe to exhaust manifold. Fit nuts and tighten to 45 Nm.
12. Fit LH under belly panel. See BODY, Repairs.
13. Remove stand(s) and lower vehicle.
14. Clean mating faces of EGR valve, inlet manifold and exhaust manifold.
15. Fit new gaskets to EGR valve and recirculation pipe. Align EGR valve to inlet manifold and exhaust manifold.
16. Fit Allen screws securing EGR valve to exhaust manifold and tighten to 25 Nm.
17. Fit 2 bolts securing EGR recirculation pipe to inlet manifold and tighten to 25 Nm.
18. Connect vacuum pipe from EGR solenoid to EGR valve.
19. Connect boost pressure sensing pipe to turbocharger.
20. Clean turbocharger oil feed pipe union and banjo bolt.
21. Fit new sealing washers to banjo bolt. Connect oil feed pipe to turbocharger and tighten union to 18 Nm.
22. Position turbocharger pipe and connect to turbocharger, tigten clip to secure.
23. Position engine lifting bracket and align turbocharger pipe to cylinder head.
24. Fit 3 bolts securing turbocharger pipe to cylinder head.
25. Connect intercooler top hose to turbocharger pipe and tighten clip.
26. Position air intake pipe and connect to turbocharger, tighten clip.
27. Connect air intake pipe to air filter and secure clips.
28. Connect breather hose to cylinder head and tighten clip.
29. Connect multiplug to air flow meter.
30. Position sound deadening pad to engine and secure with bolts.
31. Connect battery earth lead.