Exhaust Manifold - Remove and Install
Removal Procedure (Water Cooled Manifold)
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Required Tools     | |||
Tool     | Part Number     | Part Description     | Qty     |
A     | 138-7573     | Link Bracket     | 2     |
Start By:
- Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
- Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove".
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NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Loosen clamp (4). Disconnect hose (3) .
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Illustration 1 | g00677445 |
- Disconnect fitting (5) at each end and remove tube (7) .
- Remove two bolts, nuts, and washers (8) .
- Reposition temperature gauge (6) out of the way.
- Install Tool (A) with chains and a suitable lifting device to the exhaust manifold (2) .
- Remove twenty-four bolts (1) .
- Remove exhaust manifold (2) and the three gaskets.
Installation Procedure (Water Cooled Manifold)
- Use Tool (A), chains and a suitable lifting device to lift the exhaust manifold (2) into position.
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Illustration 2 | g00677445 |
- Install the three exhaust manifold gaskets and the exhaust manifold (2) .
- Apply 5P-3931 Anti-Seize Compound to the twenty-four bolts (1) .
- Install the twenty-four bolts (1) and tighten to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
- Install the temperature gauge (6). Attach with the two bolts, nuts, and washers (8) .
- Connect the fittings (5) at each end of the tube (7) .
- Connect the hose (3) and tighten the clamp (4) .
End By:
- Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install".
- Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
Removal Procedure (Air Cooled Manifold)
Start By:
- Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
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NOTICE |
---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Place a mark (A) on the exhaust manifold.
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Illustration 3 | g00858218 |
- Remove locknuts (1), washers and spacers.
- Remove exhaust manifold (2) and gaskets.
- Remove the studs that hold the exhaust manifold to the cylinder head.
Installation Procedure (Air Cooled Manifold)
- Apply 5P-3931 Anti-Seize Compound to the threads of the studs that hold the exhaust manifold to the cylinder head assembly.
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Illustration 4 | g00858218 |
- Install the studs for the cylinder head assembly. Tighten the studs to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
- Position the gaskets with the tabs in the upward position. Align mark (A). Install exhaust manifold (2) .
- Tighten bolts 1 through 12 in numerical order. Tighten bolts 1 through 12 to a torque of 38 ± 5 N·m (28 ± 4 lb ft).
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Illustration 5 | g00849408 |
End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
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