Exhaust manifold – removal and installation
1. Remove the turbocharger (see Fuel and exhaust systems – diesel engine).
2. Remove the bolts and brackets retaining the heater line (s) to the exhaust manifold (see illustration).
7.2 On models so equipped, remove the bolt retaining the heater pipe (s) to the exhaust manifold. Do not lose the spacers
3. Remove the air filter housing and the air intake hose.
4. On models so equipped, remove the heat shield/noise reduction panel from the exhaust manifold. Remove the EGR cooler (see Emissions and engine control systems).
5. Remove the rear bolt lockplates.
6. Remove the exhaust manifold bolts, exhaust manifold, gaskets and spacers (see illustration).
7.6 Remove the exhaust manifold bolts
7. Clean the mounting surfaces of the manifold and the cylinder head, and clean the threads of the exhaust manifold mounting bolts.
8. Install the manifold using new gaskets and anti-seize compound on the bolt threads. Tighten the manifold bolts a little at a time, starting with the center bolts and working outward, to the torque listed in this Chapter’s Specifications.
9. The remainder of installation is the reverse of removal. Note: The studs go in the holes for the front two cylinders and an additional one goes at the lower rear.