Exhaust Manifold — LH

Removal

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Remove the 2 top LH exhaust manifold heat shield bolts.

2. Remove the LH catalytic converter. For additional information, refer to Section 309-00 .

3. Remove the bottom bolt and the LH exhaust manifold heat shield.

4. Remove the 2 bolts and the LH upper turbocharger bracket.

5. Loosen the 2 bolts for the LH lower turbocharger bracket.

6. Remove the 3 LH turbocharger-to-exhaust manifold bolts.
   • Discard the gasket.

7. Remove the 8 nuts and the LH exhaust manifold.
   • Discard the nuts and gasket.

8. Clean and inspect the LH exhaust manifold. For additional information, refer to Section 303-00 .

9. Remove and discard the 8 LH exhaust manifold studs.

10. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

    Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

Installation

1. Install 8 new LH exhaust manifold studs.
   • Tighten to 12 Nm (106 lb-in).

2. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

   Install a new gasket, LH exhaust manifold and 8 new nuts. Tighten in 2 stages in the sequence shown:
   • Stage 1: Tighten to 15 Nm (133 lb-in).
   • Stage 2: Tighten to 20 Nm (177 lb-in).

3. Install a new gasket and the 3 turbocharger-to-exhaust manifold bolts.
   • Tighten to 45 Nm (33 lb-ft).

4. Install the upper turbocharger bracket and the 2 bolts.
   • Do not tighten the bolts at this time.

NOTICE: The next 4 steps must be performed in order or damage to the turbocharger may occur.

5. Tighten the upper turbocharger bracket-to-turbocharger bolt.
   • Tighten to 19 Nm (168 lb-in).

6. Tighten the upper turbocharger bracket-to-cylinder block bolt.
   • Tighten to 25 Nm (18 lb-ft).

7. Tighten the lower turbocharger bracket-to-turbocharger bolt.
   • Tighten to 19 Nm (168 lb-in).

8. Tighten the lower turbocharger bracket-to-cylinder block bolt.
   • Tighten to 11 Nm (97 lb-in).

9. Install the LH exhaust manifold heat shield and the bottom bolt.
   • Do not tighten the bolt at this time.

10. Install the LH catalytic converter. For additional information, refer to Section 309-00 .

11. Install the 2 top LH exhaust manifold heat shield bolts.
    • Tighten to 12 Nm (106 lb-in).

12. Tighten the LH exhaust manifold heat shield bottom bolt.
    • Tighten to 12 Nm (106 lb-in).