Exhaust Manifold Replacement Left

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable.



2. Remove the glow plugs from the cylinder head. Refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side in Engine Controls.



3. Remove the heat shield from the front of the exhaust manifold.
4. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.



5. Remove the exhaust crossover pipe bolts from the exhaust manifolds.
6. Lower the vehicle.



7. Remove the exhaust manifold and the stud/bolts. Refer toExhaust Manifold Removal (L65) .
8. Clean and check the sealing surfaces on the cylinder head. Refer to Cylinder Head Clean and Inspect .
9. Clean the threads on the exhaust manifold bolts and stud/nuts.

1. Install the exhaust manifold and stud/bolts. Refer toExhaust Manifold Installation (L65) .




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the exhaust manifold bolts and stud/nuts.

Tighten
Tighten the and stud/bolts to 35 N·m (26 lb ft).




3. Install the heat shield to the front of the exhaust manifold.

Tighten
Tighten the and stud/bolts to 11 N·m (8 lb ft).

4. Raise the vehicle.



5. Install the exhaust crossover pipe and bolts Refer to Exhaust Pipe Replacement (Crossover) in Engine Exhaust.
6. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle .
7. Install the glow plugs to the cylinder head. Refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side in Engine Controls.
8. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement .

Exhaust Manifold Replacement Right

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.



2. Remove the glow plugs from the cylinder head. Refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side in Engine Controls.



3. Remove the turbocharger assembly from the exhaust manifold. Refer to Turbocharger Replacement .



4. Remove the heat shield from the exhaust manifold.
5. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.



6. Remove the exhaust crossover pipe bolts from the exhaust manifold.
7. Disconnect the front exhaust pipe. Refer to Exhaust Pipe Replacement (Front) in Engine Exhaust.
8. Remove the safety stands and lower the vehicle.



9. Remove the exhaust manifold and stud/bolts from the cylinder head.
10. Remove the exhaust manifold from the cylinder head.
11. Clean and inspect the sealing surfaces on the cylinder head. Refer to Cylinder Head Clean and Inspect .
12. Clean the threads on the exhaust manifold bolts and stud/nuts.

1. Install the exhaust manifold to the cylinder head.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the exhaust manifold stud/bolts.

Tighten
Tighten the and stud/bolts to 35 N·m (26 lb ft).

3. Raise the vehicle and support with safety stands.



4. Install the glow plugs in the cylinder head. Refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side in Engine Controls.



5. Install the heat shield to the exhaust manifold.



6. Install the turbocharger to the exhaust manifold. Refer to Turbocharger Replacement .



7. Install the exhaust crossover pipe to the exhaust manifold. Refer to Exhaust Pipe Replacement (Crossover) in Engine Exhaust.
8. Connect the front exhaust pipe. Refer to Exhaust Pipe Replacement (Front) in Engine Exhaust.
9. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
10. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement .

Exhaust Manifold Replacement L-57

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable from the battery.



2. Remove the glow plugs from the cylinder head. Refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side in Engine Controls.
3. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the exhaust pipes from the exhaust manifolds. Refer to Exhaust Pipe Replacement (Front) in Engine Exhaust.
5. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



6. Remove the exhaust manifold stud/bolts from the left cylinder head.
7. Remove the exhaust manifold from the left cylinder head.



8. Remove the exhaust manifold stud/bolts from the right cylinder head.
9. Remove the exhaust manifold from the right cylinder head.
10. Clean and inspect the sealing surfaces of the cylinder head. Refer to Cylinder Head Clean and Inspect .

1. Install the left exhaust manifold to the cylinder head.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the exhaust manifold stud/bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).




3. Install the right exhaust manifold to the cylinder head.
4. Install the exhaust manifold stud/bolts to the right cylinder head.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).




5. Install the glow plugs to the cylinder head. Refer to Glow Plug Replacement - Left Side or Glow Plug Replacement - Right Side in Engine Controls.
6. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
7. Install the exhaust pipes to the exhaust manifolds. Refer to Exhaust Pipe Replacement (Front) in Engine Exhaust.
8. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement in Engine Electrical.