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Return Manifold, Remove and Install
 Remove
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Remove support (1) from alternator and turbocharger.
Detach wiring harness plug and vacuum lines from exhaust gas
recirculation solenoid valve (6).
Remove exhaust gas recirculation solenoid valve from intake
manifold.
Unclip fuel filter housing (5) from crash box and set aside
– fuel system remains closed.
Remove turbocharger heat shield (2) from return manifold –
3 fastening screws.
Remove fastening screws (3) for starter heat shield.
Remove lower engine compartment cover – see operation
"Lower Engine Compartment Cover, Remove and Install" in group
"A".
Release fastening nuts (4) for starter heat shield and remove
starter heat shield.
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Detach front exhaust pipe from return manifold.
Detach return manifold (1) from turbocharger – note
dissimilar bolt lengths.
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 Clean
Clean all sealing surfaces.
Install
Attach return manifold to turbocharger – note dissimilar
bolt lengths – tightening torque – 30 Nm / 22 lbf.
ft.
Attach front exhaust pipe with new gasket to exhaust manifold
– tightening torque – 20 Nm / 15 lbf. ft.
Attach heat shield to starter – tightening torque –
6 Nm / 4.5 lbf. ft.
Install lower engine compartment panelling – see operation
"Lower Engine Compartment Cover, Remove and Install" in group
"A".
Attach turbocharger heat shield and return manifold –
tightening torque – 8 Nm / 6 lbf. ft.
Clip fuel filter housing into crash box.
Attach exhaust gas recirculation solenoid valve to intake
manifold – tightening torque – 8 Nm / 6 lbf. ft.
Attach wiring harness plug and vacuum hoses to exhaust gas
recirculation solenoid valve.
Attach alternator bracket to turbocharger and install alternator
– tightening torque – 18 Nm / 13 lbf. ft.
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