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Exhaust Manifold with Turbocharger, Remove and
Install
 Remove
Remove upper engine cover.
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Remove charge air pipe - see illustration "Air duct X 20 DTL, Y
20 DTL" or "Air duct Y 20 DTH up to MY 2003" or "Air duct Y 20 DTH
as of MY 2003, Y 22 DTR".
For Y 22 DTR engine -detach wiring harness plug (1) from vacuum
container solenoid.
Detach wiring harness plug (2) from charge pressure control
solenoid valve.
Detach wiring harness plug (5) from glow plugs using KM-717.
Remove fastening bolts (3) and (4) from wiring trough (6). Lay
wiring trough aside.
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Remove air cleaner housing with hot film mass air flow meter and
air intake hose (1) - see illustration "Air duct X 20 DTL, Y 20
DTL" and "Air duct Y 20 DTH up to MY 2003" and "Air duct Y 20 DTH
as of MY 2003, Y 22 DTR".
Remove fastening bolts (2) and centre heat shield. Remove
fastening bolts (3) and remove left and right heat shields.
Remove lower engine compartment cover – see operation
"Lower Engine Compartment Cover, Remove and Install" in group
"A".
Remove fastening bolts (7) and (8) for heat shield and remove
heat shield.
Remove exhaust manifold support (6) from exhaust manifold (4)
and detach from cylinder block – swing support aside.
Detach turbocharger oil return line (5) from cylinder block.
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Detach wiring trough (1) and turbocharger oil feed line (2) from
cylinder block – place collecting basin underneath.
Detach front exhaust pipe from return manifold - front exhaust
pipe must be protected from sagging - even flexible pipe bending of
10 - 15° can cause damage leading to subsequent total failure
of flexible pipe!
Detach turbocharger oil feed line from turbocharger and remove
upwards.
In X 20 DTL, Y 20 DTL and Y 20 DTH: detach vacuum hose from
wastegate unit.
In Y 22 DTR: Detach vacuum line from turbine wheel adjustment
vacuum unit.
Detach exhaust manifold from cylinder head and remove upwards
with turbocharger.
When replacing exhaust manifold: Detach turbocharger from
exhaust manifold – see operation "Turbocharger, Remove and
Install".
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 Clean
Clean sealing surfaces and remove gasket residues.
Install
Attach exhaust manifold to cylinder head with new gasket and new
fastening nuts – tightening torque 22 Nm / 16 lbf. ft.
In Y 22 DTR: Attach vacuum line to turbine wheel adjustment
vacuum unit.
In X 20 DTL, Y 20 DTL, Y 20 DTH: attach vacuum hose to wastegate
unit.
Attach turbocharger oil return line to cylinder block –
tightening torque 20 Nm / 15 lbf. ft.
Slacken retainer and attach exhaust pipe to return manifold with
new gasket and new fastening nuts - tightening torque 20 Nm / 15
lbf. ft.
Attach turbocharger oil feed line to turbocharger with new seal
rings – tightening torque 20 Nm / 15 lbf. ft.
Attach turbocharger oil feed line to cylinder block –
tightening torque 20 Nm / 15 lbf. ft.
Attach exhaust manifold support to exhaust manifold and cylinder
block – tightening torque 25 Nm / 18.5 lbf. ft.
Attach wiring trough to cylinder block (three fastening
bolts).
Install starter heat shield.
Install lower engine compartment cover – see operation
"Lower Engine Compartment Cover, Remove and Install" in group
"A".
Install all heat shields.
Attach wiring trough to cylinder head cover and bracket.
Attach wiring harness plug to glow plugs and charge pressure
control solenoid valve.
For Y 22 DTR engine: attach wiring harness plug to vacuum holder
solenoid valve.
Install charge air pipe with new O-ring - see illustration "Air
duct X 20 DTL, Y 20 DTL" and "Air duct Y 20 DTH up to MY 2003" and
"Air duct Y 20 DTH as of MY 2003, Y 22 DTR".
Install upper engine cover.
Install air cleaner housing with hot film mass air flow meter
and air intake hose (1) - see illustration "Air duct X 20 DTL, Y 20
DTL" and "Air duct Y 20 DTH up to MY 2003" and "Air duct Y 20 DTH
as of MY 2003, Y 22 DTR".
Inspect
Check engine oil level and correct if necessary.
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