Exhaust manifold fittings
1 - heat shield; 2 - oxygen sensor; 3 - radiator; 4 - collector heat shield; 3 - lifting bracket; 6 - exhaust manifold; 7 - air intake hose; 8 - gasket; 9 - air hose; 10 - lifting bracket; 11, 12 - cooling system hose.
Removing
ATTENTION: This work is carried out only on a cold engine.
Disconnect the ground wire from the battery.
Drain the coolant from the cooling system.
After disconnecting the upper and lower coolant hoses from the engine, remove the radiator together with the hoses attached to it. Do not remove the electric fan from the radiator casing.
Using a special collet, carefully remove the oxygen sensor (lambda probe).
Place the sensor in a protected location.
Disconnect the air intake hose from the turbocharger (if installed).
Once marked, remove the small vacuum hoses from the turbocharger.
Disconnect the air hose from the turbocharger (if installed).
Remove the heat shield from the top of the manifold.
Remove the heat shield from the front and sides of the turbocharger.
After undoing the two nuts securing the engine lift bracket, remove this bracket.
Disconnect the eyebolt above the turbocharger. Remove and discard two washers (gaskets) this connection.
Once marked, remove the coolant hose from the turbocharger. Carefully unscrew and remove the water pipe fitting (12) and turbocharger. Do not break the fitting while removing the fitting.
After removing the exhaust pipe bracket bolt, remove the self-locking nuts securing the exhaust pipe to the turbocharger (if there).
Carefully separate the pipe from the turbocharger and remove the gasket from the connection.
Loosen the exhaust manifold nuts and bolts.
Remove the manifold, its gasket and O-ring, hang the turbocharger with a piece of wire or rope.
Carefully inspect the manifold for cracks and damage. Using a ruler and a set of feeler gauges, check the surface of the cylinder head for warping. The maximum allowed distortion is 0.3 mm.
Installation
Install a new manifold gasket.
Installation is carried out in the reverse order.