Removal and Replacement

Replacing the exhaust manifold

Special tools:
999 2901 FUEL HOSE PLIERS 999 2901 Fuel Hose Pliers

Removing the exhaust manifold






Remove:
- the exhaust manifold and firewall heat shields
- the relay cover
- the bracket for the exhaust manifold
- the front heated oxygen sensor (HO2S). See Replacing lambda sonde front Removal and Replacement
- the turbocharger (TC) from the exhaust manifold. (Remove the 3 nuts on the top. Remove the 1 nut on the underside)
- the rear engine cover
- the front exhaust pipe
- the bracket for the oil pipe
- the connection for the upper oil pipe
- the nuts for the exhaust manifold
- the hose at the air cleaner. The hose for the charge air cooler (CAC).
Clamp both radiator hoses using hose clips 999 2901 FUEL HOSE PLIERS 999 2901 Fuel Hose Pliers. Slacken off both the connections at the turbocharger (TC).
Move the turbocharger (TC) backwards. Lift the lower oil pipe out of the cylinder block.
Remove the exhaust manifold and the gasket.

Installing the exhaust manifold

Installation





Note! Use new gaskets and O-rings.

Clean the mating surfaces.
Install the exhaust manifold. Use new gaskets.
Secure the exhaust manifold to the cylinder head. Tighten to 25 Nm. Begin tightening from the center.
Install the support bracket for the exhaust manifold. Tighten to 24 Nm.
Clean the surface thoroughly.
Insert the lower oil pipe in the cylinder block. Use a new O-ring. Secure the turbocharger (TC) to the exhaust manifold. Tighten to 45 Nm. One of the nuts must be tightened from underneath.

Install:
- the upper oil pipe connection. Tighten to 24 Nm
- both radiator connections. Tighten to 25 Nm. Remove the hose clips
- the front heated oxygen sensor (HO2S). See Replacing lambda sonde front Removal and Replacement
- the exhaust manifold and firewall heat shields
- the hose at the air cleaner. The hose for the charge air cooler (CAC)
- the engine cover. The relay cover
- the bracket for the oil pipe
- the front exhaust pipe. Use a new gasket. See Replacing the turbocharger (TC) Replacing The Turbocharger (TC)
- the rear engine cover.