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Exhaust Manifold Replacement - Left Side (LAU/A28NER)

Exhaust Manifold Replacement - Left Side (LAU/A28NER)

Removal Procedure


1. Remove the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

4. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

6. Drain the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .

7. Lower the vehicle.

8. Remove the catalytic converter front heat shield (1).


9. Remove the transmission heat shield (1).


10. Remove the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement .

11. Remove the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

12. Remove the secondary air injection inlet pipe. Refer to Secondary Air Injection Pipe Replacement .

13. Remove the generator. Refer to Generator Replacement (Diesel) Generator Replacement (LAU/A28NER) Generator Replacement (LLU/A16LET) Generator Replacement (LHU/A20NFT) .

14. Remove the secondary air injection pump. Refer to Secondary Air Injection Pump Replacement .

15. Remove the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement .

16. Remove the turbocharger coolant feed pipe (1).


17. Remove the 4 exhaust front manifold heat shield fasteners (1).


18. Remove the exhaust front manifold heat shield (2).

19. Remove the 3 exhaust manifold brace fasteners (1).


20. Remove the exhaust turbocharger inlet pipe fasteners (1).


21. Remove the exhaust turbocharger inlet pipe (2).

22. Remove the 2 secondary air injection pipe fasteners (1).


23. Remove the 7 exhaust front manifold fasteners (1).


24. Remove the exhaust front manifold (2).

25. Remove the exhaust front manifold gasket (3).

26. Clean all of the gasket surfaces.


Installation Procedure


1. Install the NEW exhaust front manifold gasket (3).


2. Install the exhaust front manifold (2).

3. Refer to Fastener Caution .

Install the 7 fasteners to the front exhaust pipe (1) and tighten to 25 Nm (18 lb ft) .

4. Install a NEW secondary air injection pipe gasket.


5. Fit the two fasteners to the secondary air, injection pipe bolts (1) and tighten to 10Nm (89 lb in) .

6. Install a NEW exhaust turbocharger inlet pipe gasket.


7. Install the exhaust turbocharger inlet pipe (2).

8. Install the turbocharger intake manifold fasteners (1) and tighten to 30 Nm (22 lb ft) .

9. Install the 3 fasteners to the exhaust manifold(1) and tighten to 30 Nm (22 lb ft) .


10. Install the exhaust front manifold heat shield (2).


11. Install the 4 exhaust front manifold heat shield fasteners (1) and tighten to 10 Nm (89 lb in) .

12. Install the turbocharger coolant delivery pipe (1) and tighten the M12 to 30 Nm (22 lb ft) and then the M14 to 35 Nm (26 lb ft) .


13. Install the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement .

14. Install the secondary air injection pump. Refer to Secondary Air Injection Pump Replacement .

15. Install the generator. Refer to Generator Replacement (Diesel) Generator Replacement (LAU/A28NER) Generator Replacement (LLU/A16LET) Generator Replacement (LHU/A20NFT) .

16. Install the secondary air injection inlet pipe. Refer to Secondary Air Injection Pipe Replacement .

17. Install the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement .

18. Install the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement .

19. Install the transmission heat shield (1).


20. Install the catalytic converter front heat shield (1).


21. Raise the vehicle.

22. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

23. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

25. Install the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

26. Fill the cooling system. Refer to Cooling System Draining and Filling (LAU/A28NER) Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LHU/A20NFT) .