Exhaust manifold
Exhaust manifold |
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To remove |
1. |
Lay out wing covers and remove the negative cable from the battery.
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2. |
Remove the engine cover and charge air pipe (2 bolts under wiring harness). Plug the hoses.
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3. |
Remove the bracket on the camshaft cover
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4. |
Remove the electric connections from the glow plugs.
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5. |
Remove the crankcase ventilation hose and the intake hose from the turbocharger.
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7. |
Remove the wiring harness duct from the engine and move it forward.
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8. |
Remove the nuts securing the front exhaust pipe to the turbocharger.
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9. |
Raise the car and remove the lower cover.
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10. |
Loosen the joint between the front exhaust pipe and the middle pipe.
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11. |
Remove the front rubber mountings and lower the exhaust pipe.
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12. |
Position a container underneath the engine and remove the oil delivery pipe for the turbocharger from the cylinder block.
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13. |
Remove the oil return pipe for the turbocharger from the cylinder block.
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14. |
Remove the upper bolt securing the exhaust manifold support, and slacken the lower bolt so that the support can be moved aside. Lower the car.
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15. |
Disconnect the vacuum hose from the wastegate diaphragm unit, remove the exhaust manifold and lift out the turbocharger and exhaust manifold.
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16. |
Remove the turbocharger from the exhaust manifold.
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To fit |
1. |
Clean the sealing surfaces, apply Molycote 1000 on the sealing surfaces and on the studs, fit the turbocharger on the exhaust manifold.
Tightening torque 30 Nm (22 lbf ft). |
2. |
Clean the sealing surfaces, apply Molycote 1000 on the studs and fit the exhaust manifold to the cylinder head using a new gasket and new nuts.
Tightening torque 22 Nm (16 lbf ft). |
3. |
Connect the vacuum hose to the idle air control valve diaphragm unit.
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4. |
Apply Molycote 1000 on the turbocharger studs.
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5. |
Raise the car. Reposition the exhaust manifold support and tighten the bolts.
Tightening torque 25 Nm (18.5 lbf ft). |
6. |
Connect the turbocharger oil return pipe to the cylinder block.
Tightening torque 30 Nm (22 lbf ft). |
7. |
Connect the oil delivery pipe for the turbocharger to the cylinder block.
Tightening torque 20 Nm (15 lbf ft). |
8. |
Clean the exhaust pipe joints and fit new rubber mountings if needed.
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9. |
Fit the front part of the exhaust pipe using a new gasket and fit new nuts.
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10. |
Tighten the exhaust pipe to the middle pipe.
Tightening torque 20 Nm (15 lbf ft). |
11. |
Fit the cover and lower the car.
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12. |
Tighten the nuts securing the turbocharger and the front exhaust pipe.
Tightening torque 20 Nm (15 lbf ft). |
13. |
Remove the oil delivery pipe connection from the turbocharger and fill the turbocharger oil channel with engine oil. Turn the turbocharger shaft a few times and top up if needed.
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14. |
Tighten the oil delivery pipe connection to the turbocharger using new sealing washers.
Tightening torque 20 Nm (15 lbf ft). |
15. |
Refit the wiring harness duct to the engine.
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16. |
Refit the heat shields over the exhaust manifold, turbocharger and starter motor. Tighten the bolt on the lifting eye.
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17. |
Connect the suction hose to the turbocharger and crankcase ventilation hose.
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18. |
Connect the glow plugs.
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19. |
Fit the bracket to the camshaft cover.
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20. |
Fit the charge air pipe.
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21. |
Fit the engine cover.
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22. |
Connect the negative cable to the battery.
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23. |
Adjust the clock in the car and press 5 times on the remote control lock/unlock button.
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24. |
Check the oil level and top up if needed.
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25. |
Start the engine and check for leakage.
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