Diesel Data: Automotive Repair

Exhaust Manifold LH


Exhaust Manifold LH

Service Repair No - 30.15.10

Removal
All vehicles
1. Disconnect the battery ground cable.
2. Remove the engine cover.

Right-hand drive vehicles





1. Release the battery positive cable.
^ Loosen the clamp.
^ Release the grommet.

Right-hand drive vehicles





1. Release the wiring harness clip.
^ Remove the bolt.

All vehicles

1. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.
2. Remove the engine undershield.





3. Release the exhaust system from the exhaust manifold.
^ Remove and discard the 2 bolts.
4. Lower the vehicle.





5. CAUTION: Protect the engine during this operation.

Raise the engine clear of its LH mount.
^ Remove the nut.





6. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

Remove the EGR pipe.
^ Release the 2 union nuts.





7. Disconnect the high tension (HT) electrical connectors.
^ Move the leads aside for access.





8. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

Remove the dipstick tube.
^ Remove the dipstick.
^ Remove the bolt.
^ Discard the O-ring seal.





9. Remove the exhaust manifold.
^ Remove the 6 nuts.
^ Remove and discard the gasket.

Installation
All vehicles





1. NOTE: The exhaust manifold gasket connecting links must be positioned to the lower edge of the manifold.

Install the exhaust manifold.
^ Install a new gasket.
^ Clean the component mating faces.
^ Tighten the nuts evenly in the sequence shown to 25 Nm (18 ft. lbs.).
2. Install the dipstick tube.
^ Clean the component mating faces.
^ Install a new O-ring seal.
^ Lubricate the seal with clean engine oil.
^ Tighten the bolt to 10 Nm (7 ft. lbs.).
^ Install the dipstick.
3. Connect the HT electrical connectors.
4. Install the EGR pipe.
^ Clean the component mating faces.
^ Initially, finger tighten the nuts.
^ Finally, tighten the nuts to 40 Nm (30 ft. lbs.).
5. Lower the engine onto its mount.
^ Tighten the nut to 90 Nm (66 ft. lbs.).
6. Raise the vehicle.
7. Install the exhaust system.
^ Clean the component mating faces.
^ Install new bolts and tighten to 40 Nm (30 ft. lbs.).
8. Install the engine undershield.
9. Lower the vehicle.

Right-hand drive vehicles

1. NOTE: Apply petroleum jelly to the battery terminals.

Connect the battery positive cable.
^ Clean the component mating faces.
^ Install the grommet.
^ Tighten the clamp nut to 10 Nm (7 ft. lbs.).

Right-hand drive vehicles
1. Secure the wiring harness clip.
^ Tighten the bolt to 10 Nm (7 ft. lbs.).

All vehicles
1. Install the engine cover.
2. Connect the battery ground cable.