Removal and Installation

Special Tool:

SPECIAL TOOL
This procedure requires the use of special tool# 103 589 01 39 00 (caulking bolt) or equivalent.

PRECEDING WORK
Before removing the intake manifold, the following components must be removed:
a. Bottom engine compartment panel.
b. Air cleaner assembly,
These components must be reinstalled after replacing the intake manifold.

Replacing Exhaust Manifold:

REMOVAL
1. Remove down pipe bolts (158/1).
2. Remove exhaust bracket carrier at transmission.
3. Remove EGR line (89/2).
4. Remove vacuum line (89/3).
5. Remove shields (155/1 and 155/2).
6. Remove air injection vacuum line (arrow) and hose (125/3).
7. Unscrew bolts with spacer (129/1 and 129/2) and remove air injection pipe (129).
8. Remove nuts (156/1).
9. Remove exhaust manifolds (156).





INSTALLATION
1. Replace riveted nuts in exhaust manifold. Use a suitable bolt to knock out the old rivets. Screw in bolt by hand only.

Installing Riveted Nut:

2. Install new riveted nuts. Use special tool (caulking bolt 103 589 01 39 00 or equivalent) and torque nuts to:

30 Nm (22 ft.lb.)

3. Replace manifold gaskets. Apply sealing compound to gasket.

NOTE: Insert gaskets with sheet metal side towards cylinder head.

4. Replace all other gaskets and seals.
5. Replace manifold nuts (156/1).
6. Install manifolds and torque new nuts (156/1) to:

40 Nm (29.5 ft.lb.)

7. Install all other components in reverse order. Torque exhaust bracket carrier at transmission to:

20 Nm (15 ft.lb.)

Torque down pipe to manifold bolts to:

30 Nm (22 ft.lb.)

8. When engine is running, check for leaks.