Exhaust manifold
Warning. Allow the engine to cool completely before starting the procedure.
Removal
1. The exhaust manifold is located at the rear of the cylinder head. Start by removing the turbocharger as described in chapter 4B.
2. Loosen the exhaust manifold and cylinder head mounting bolts and remove the EGR heat exchanger pipe, then remove the gaskets (see Figure 6.2, a-c).
Figure 6.2,a. Loosen the mounting bolts and remove the exhaust gas recirculation tube...
Figure 6.2, b....and remove the gaskets from the exhaust manifold...
Figure 6.2, c....and cylinder heads.
3. Lubricate the exhaust manifold mounting nuts with penetrating lubricant, then unscrew them and separate the exhaust manifold from the cylinder head. Remove the gaskets and bushings (see figure 6.3,a,b).
Figure 6.3,a. Loosen the fastening nuts and remove the bushings...
Figure 6.3,b....then remove the exhaust manifold.
Installation
4. Using a scraper, remove any remaining old gasket and carbon deposits from the mating surfaces of the exhaust manifold and cylinder head. If the gasket shows signs of leakage, check the mating flange for warpage using a steel ruler and a set of flat feeler gauges. In case of significant curvature (see Specifications) the exhaust manifold must be replaced.
5. Place the new gasket, aligning it with the guide pins on the cylinder head, then install the exhaust manifold, after replacing the gaskets and sealing rings, and tighten the mounting nuts. Gradually tighten the mounting nuts to the specified torque (see Figure 6.5, a-c).
Figure 6.5,a. Place a new gasket on the cylinder head studs...
Figure 6.5,6. ...then install the exhaust manifold...
Figure 6.5, c....making sure that bushings are installed under the nuts.
6. Install the EGR cooler pipe with a new gasket and tighten the mounting bolts/nuts.
7. Install the turbocharger as described in chapter 4B.
8. Start the engine and check for exhaust leaks.