When servicing or repairing an exhaust manifold, first pull out the battery negative terminals and put the car on a hoist. Remove the pipe from the turbocharger elbow on the exhaust and take out the toll drain tube, then lower the vehicle. Go ahead and disconnect the air inlet hose from the electronic wastegate command valve, the harness from the wastegate command valve and then unhook the air cleaner assembly. Detach the supply line bringing turbocharger oil and the charge air cooler pipe that goes into the turbocharger. Take off the turbocharger and gasket from above the exhaust manifold, then take the nuts from the cab heater return pipe out of the stud in the manifold before pushing the tube aside. Take off the heat shield, the bolt lockplates from the exhaust manifold and the exhaust manifold bolts and spacers. Scrape and clean the cylinder head and exhaust manifold sealing surfaces with either a scraper or a Scotch-Brite pad. See if there are any cracks in the exhaust manifold and measure it so that it doesn't deviate more than 0.20 mm (0.008 inch) from being flat. When installing, fit new gaskets between the exhaust manifold and engine head, after which you should proceed to bolt them on and tighten them to 43 Nm (32 ft. lbs.) in the instructed pattern. Replace the four center bolts, set the heat shield and torque nuts to 24 Nm (18 ft. lbs.) and apply the cab heater tube and exhaust manifold bolt retention straps. Place the cab heater return hose on the manifold bolt stud and tighten its nut to 24 Nm (18 ft. lbs.) torque. Assemble the turbocharger using a new gasket and use torque of 43 Nm (32 ft. lbs.) for the mounting nuts. Lift the vehicle once more and place the oil drain tube with a new gasket, tighten its bolts to 24 Nm (18 ft. lbs.). Connect the
Exhaust Pipe to the turbo charger and fasten the bolts to 11 Nm (100 ft. lbs.) torque, then hook up the wastegate command valve and return the vehicle to the ground. Pour 50 to 60 cc (2 to 3 ounces) of clean engine oil into the oil supply line fitting on the turbocharger and use your hand to turn the turbocharger impeller until the oil is well distributed. Secure the oil supply line fitting nut to 24 Nm (18 ft. lbs.), put the charge air cooler inlet pipe on the turbocharger and clamp it with 11 Nm (95 inch lbs.) torque and then secure the air inlet hose to the turbocharger with a clamp tightened to 4 Nm (35 inch lbs.) torque. When everything is done, reconnect the car's negative
Battery Cables and switch on the engine to examine the area for leaks.