Exhaust Manifold and Inlet Manifold – Remove and Install


Exhaust Manifold

Removal Procedure (Side Mounted Exhaust Manifold)


Remove the turbocharger.


Loosen the setscrews (2) and (5) in reverse numerical order. This will help prevent distortion of the exhaust manifold.
Remove the center four setscrews (2) from the exhaust manifold (3). Remove the outer eight setscrews (5) and the spacers (4) from the exhaust manifold (3). Support the manifold as the setscrews are removed.
Remove the exhaust manifold (3).
Remove the two exhaust manifold gaskets (1). Discard the gaskets.
If necessary, remove the four studs (6) from the exhaust manifold (3).

Removal Procedure (Top Mounted Exhaust Manifold)


Disconnect all hoses, tube assemblies and wire leads from the turbocharger.


Loosen the setscrews (2) and (5) in reverse numerical order.
Remove the center four setscrews (2) from the exhaust manifold (3). Remove the outer eight setscrews (5) and the spacers (4) from the exhaust manifold (3). Remove the assembly of the exhaust manifold (3) and the turbocharger.
Remove the two exhaust manifold gaskets (1). Discard the gaskets.
Remove the turbocharger from the exhaust manifold (3).
If necessary, remove the four studs (6) from the exhaust manifold (3).

Installation Procedure (Side Mounted Exhaust Manifold)

See Remove procedure illustrations.
Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the joint face of the cylinder head.
If necessary, install the four studs (6) to the exhaust manifold (3). Tighten the studs to a torque of 18 N·m (13 lb ft).
Install Tooling to the cylinder head in the positions (X).
Position two new exhaust manifold gaskets (1) onto Tooling. Ensure that the word TOP is outward and upward.
Align the exhaust manifold (3) with Tooling. Install the exhaust manifold to the cylinder head.
If the setscrews (2) and (5) have been previously used, the setscrews should be thoroughly cleaned. Tooling should be applied to the first two threads of the setscrews.
Install the setscrews (2) finger tight. Install the setscrews (5) and the spacers (4) finger tight.
Remove Tooling. Install the remaining setscrews (2) finger tight. Install the remaining setscrews (5) and spacers (4) finger tight.
Tighten the setscrews (2) and (5) to a torque of 44 N·m (32 lb ft). Tighten the setscrews in the sequence that is shown in Illustration.

Installation Procedure (Top Mounted Exhaust Manifold)

See Remove procedure illustrations.
Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the joint face of the cylinder head.
If necessary, install the four studs (6) to the exhaust manifold (3). Tighten the studs to a torque of 18 N·m (13 lb ft).
Install the turbocharger to the exhaust manifold.
Install Tooling to the cylinder head in the positions (X).
Position two new exhaust manifold gaskets (1) onto Tooling.
Align the exhaust manifold (3) with Tooling. Install the exhaust manifold to the cylinder head.
If the setscrews (2) and (5) have been previously used, the setscrews should be thoroughly cleaned. Tooling should be applied to the first two threads of the setscrews. Do not apply Tooling  to new setscrews.
Install the setscrews (2) finger tight. Install the setscrews (5) and the spacers (4) finger tight.
Remove Tooling. Install the remaining setscrews (2) finger tight. Install the remaining setscrews (5) and spacers (4) finger tight.
Tighten the setscrews (2) and (5) to a torque of 44 N·m (32 lb ft). Tighten the setscrews in the sequence that is shown in Illustration.
Connect all hoses, tube assemblies and wire leads from the turbocharger.


Inlet Manifold

Removal Procedure

If necessary, remove the fuel filter base. Remove the fuel manifold.
Remove the ECM mounting bracket. Remove the boost pressure sensor.
Remove the air inlet temperature sensor.
Disconnect the breather hose from the separator for the crankcase breather.


Cut the cable ties that secure the harness assembly to the inlet manifold (4). Position the harness assembly away from the inlet manifold.
Remove the setscrews (1) from the inlet connection (2).
Remove the inlet connection (2) and the gasket (3) from the inlet manifold (4). Discard the gasket. Remove the setscrews (5).
Remove the inlet manifold (4) from the cylinder head. Use a suitable tool to pry the inlet manifold from the cylinder head. Use the recess at position (X) to pry the inlet manifold.
Remove the inlet manifold seal (6) from the recess in the inlet manifold (4). Discard the seal. Do not remove the two dowel pins (7).

Installation Procedure


Ensure that the inlet manifold is clean and free from damage. If necessary, replace the inlet manifold. If a new inlet manifold is installed, install two new dowel pins (7) to the inlet manifold (4). Do not install dowel pins to the cylinder head. Clean the joint face of the cylinder head.
Align the tag (8) to the slot at position (Y) on the inlet manifold. Install the new seal (6) to the groove in the inlet manifold (4). Ensure that the seal is correctly located.
Align the dowel pins (7) to the holes in the cylinder head. Install the inlet manifold (4) to the cylinder head. Apply Tooling to the setscrews (5). Install the setscrews to the inlet manifold (4).


Tighten the setscrews to a torque of 22 N·m (16 lb ft) in the sequence that is shown in Illustration.
Ensure that the inlet connection (2) is clean and free from damage. If necessary, replace the inlet connection.
Position a new gasket (3) onto the inlet manifold. Install the inlet connection (2) to the inlet manifold (4). Install setscrews (1) to the inlet connection (2). Tighten the setscrews to a torque of 22 N·m (16 lb ft).
Install the air temperature sensor. Install the boost pressure sensor.
Position the harness assembly on the inlet manifold. Use new cable ties in order to secure the harness assembly.
Connect the breather hose to the separator for the crankcase breather.
Install the ECM mounting bracket. Install the fuel manifold.
If necessary, install the fuel filter base.