Saab 2000-06

Exhaust Manifold

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Removal & Installation



2.0L Engines
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableTurbocharger and relieve tension on the belt tensionerDrive beltSteering servo pump and bracketExhaust manifold and discard the gasket

    Negative battery cable
     
    Turbocharger and relieve tension on the belt tensioner
     
    Drive belt
     
    Steering servo pump and bracket
     
    Exhaust manifold and discard the gasket
     

  6.  
  7. Clean all mating surfaces of any residual gasket material.
  8.  

To install:

  1. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)Steering servo pump and bracketDrive beltTurbochargerNegative battery cable

    Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Steering servo pump and bracket
     
    Drive belt
     
    Turbocharger
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Turbocharger
     
    Drive belt
     
    Steering servo pump and bracket
     
    Exhaust manifold and discard the gasket
     

  6.  
  7. Clean all mating surfaces of any residual gasket material.
  8.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Steering servo pump and bracket
     
    Drive belt
     
    Turbocharger
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Turbocharger and relieve tension on the belt tensioner
     
    Drive belt
     
    Steering servo pump and bracket
     
    Exhaust manifold and discard the gasket
     

  6.  
  7. Clean all mating surfaces of any residual gasket material.
  8.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Steering servo pump and bracket
     
    Drive belt
     
    Turbocharger
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2.3L Engines
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableLower front coverTurbocharger-to-block mounting boltTurbocharger upper mounting boltTurbocharger coolant pipeTurbocharger return hoseOil pipe from the turbocharger to the oil filter adapterBypass pipe and valveExhaust manifold heat shieldSolenoid connectorMAF sensor-to-turbocharger connecting hoseCrankcase breather pipe (bend pipe aside)Solenoid valve hoses (note positions)Engine lifting eyeTurbocharger intake pipe from V-clamp (plug turbocharger inlet opening)2 upper nuts between turbocharger and front exhaust pipe (move exhaust aside)Turbocharger coolant return pipe from cylinder head and pressure sensor mountWastegate from turbochargerNuts holding turbocharger to exhaust manifold (slightly lower turbocharger)Relieve auxiliary drive belt tensionerAuxiliary drive belt from power steering pump pulleyThrough-bolts, lower bolt and 2 upper bolts holding power steering pump (lift pump and bracket aside)Exhaust manifold

    Negative battery cable
     
    Lower front cover
     
    Turbocharger-to-block mounting bolt
     
    Turbocharger upper mounting bolt
     
    Turbocharger coolant pipe
     
    Turbocharger return hose
     
    Oil pipe from the turbocharger to the oil filter adapter
     
    Bypass pipe and valve
     
    Exhaust manifold heat shield
     
    Solenoid connector
     
    MAF sensor-to-turbocharger connecting hose
     
    Crankcase breather pipe (bend pipe aside)
     
    Solenoid valve hoses (note positions)
     
    Engine lifting eye
     
    Turbocharger intake pipe from V-clamp (plug turbocharger inlet opening)
     
    2 upper nuts between turbocharger and front exhaust pipe (move exhaust aside)
     
    Turbocharger coolant return pipe from cylinder head and pressure sensor mount
     
    Wastegate from turbocharger
     
    Nuts holding turbocharger to exhaust manifold (slightly lower turbocharger)
     
    Relieve auxiliary drive belt tensioner
     
    Auxiliary drive belt from power steering pump pulley
     
    Through-bolts, lower bolt and 2 upper bolts holding power steering pump (lift pump and bracket aside)
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)Power steering pump and bracket. Torque the upper left mounting bolt to 18 ft. lbs. (24 Nm) first then torque the remaining bolts to the same specificationAuxiliary drive belt to power steering pump pulley and tighten it with the tensioner

    Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Power steering pump and bracket. Torque the upper left mounting bolt to 18 ft. lbs. (24 Nm) first then torque the remaining bolts to the same specification
     
    Auxiliary drive belt to power steering pump pulley and tighten it with the tensioner
     

  2.  


NOTE
Fill the turbo inlet with oil. Rotate the compressor wheel by hand several times to assure the bearings are well lubricated.



Turbocharger to the exhaust manifold and torque the lock nuts to 18 ft. lbs. (24 Nm) and the studs to 16 ft. lbs. (22 Nm)
 
Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
 
Wastegate
 
Coolant return pipe to turbocharger with new copper washers and torque the bolts to 19 ft. lbs. (25 Nm)
 
Coolant return pipe to cylinder head and torque bolts to 19 ft. lbs. (25 Nm)
 
Turbocharger intake pipe with a new lubricated O-ring to the power steering pump bracket. Torque the bolt and adjusting screw to 18 ft. lbs. (24 Nm).
 
Coolant pipe to turbocharger, with new sealing washers, and torque to 19 ft. lbs. (25 Nm)
 
Oil pipe from turbo to oil filter adapter, with new washers, and torque to 19 ft. lbs. (25 Nm)
 
Turbocharger-to-block upper bolt then remaining bolt torqued to 18 ft. lbs. (24 Nm)
 
Lower nut on joint between turbocharger and exhaust pipe
 
Intake pipe with lifting eye to turbocharger
 
Solenoid valve hoses
 
Solenoid valve connector
 
Crankcase-to-camshaft cover and turbo intake pipe and torque the bolts to 18 ft. lbs. (24 Nm)
 
MAF sensor-to-turbocharger intake pipe hose
 
Bypass hose and valve with new O-ring
 
Exhaust manifold heat shield
 
Negative battery cable
 

  1. Fill the cooling system and bleed by running engine (A/C off), at varying speeds, until cooling fan comes on. Stop the engine and top up the coolant.
  2.  
  3. Check and adjust level of engine oil
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Lower front cover
     
    Turbocharger-to-block mounting bolt
     
    Turbocharger upper mounting bolt
     
    Turbocharger coolant pipe
     
    Turbocharger return hose
     
    Oil pipe from the turbocharger to the oil filter adapter
     
    Bypass pipe and valve
     
    Exhaust manifold heat shield
     
    Solenoid connector
     
    MAF sensor-to-turbocharger connecting hose
     
    Crankcase breather pipe (bend pipe aside)
     
    Solenoid valve hoses (note positions)
     
    Engine lifting eye
     
    Turbocharger intake pipe from V-clamp (plug turbocharger inlet opening)
     
    2 upper nuts between turbocharger and front exhaust pipe (move exhaust aside)
     
    Turbocharger coolant return pipe from cylinder head and pressure sensor mount
     
    Wastegate from turbocharger
     
    Nuts holding turbocharger to exhaust manifold (slightly lower turbocharger)
     
    Relieve auxiliary drive belt tensioner
     
    Auxiliary drive belt from power steering pump pulley
     
    Through-bolts, lower bolt and 2 upper bolts holding power steering pump (lift pump and bracket aside)
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Fill the turbo inlet with oil. Rotate the compressor wheel by hand several times to assure the bearings are well lubricated.



    Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Power steering pump and bracket. Torque the upper left mounting bolt to 18 ft. lbs. (24 Nm) first then torque the remaining bolts to the same specification
     
    Auxiliary drive belt to power steering pump pulley and tighten it with the tensioner
     



    Turbocharger to the exhaust manifold and torque the lock nuts to 18 ft. lbs. (24 Nm) and the studs to 16 ft. lbs. (22 Nm)
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Wastegate
     
    Coolant return pipe to turbocharger with new copper washers and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Coolant return pipe to cylinder head and torque bolts to 19 ft. lbs. (25 Nm)
     
    Turbocharger intake pipe with a new lubricated O-ring to the power steering pump bracket. Torque the bolt and adjusting screw to 18 ft. lbs. (24 Nm).
     
    Coolant pipe to turbocharger, with new sealing washers, and torque to 19 ft. lbs. (25 Nm)
     
    Oil pipe from turbo to oil filter adapter, with new washers, and torque to 19 ft. lbs. (25 Nm)
     
    Turbocharger-to-block upper bolt then remaining bolt torqued to 18 ft. lbs. (24 Nm)
     
    Lower nut on joint between turbocharger and exhaust pipe
     
    Intake pipe with lifting eye to turbocharger
     
    Solenoid valve hoses
     
    Solenoid valve connector
     
    Crankcase-to-camshaft cover and turbo intake pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    MAF sensor-to-turbocharger intake pipe hose
     
    Bypass hose and valve with new O-ring
     
    Exhaust manifold heat shield
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system and bleed by running engine (A/C off), at varying speeds, until cooling fan comes on. Stop the engine and top up the coolant.
  4.  
  5. Check and adjust level of engine oil
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

9-5 Models-2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Lower front cover
     
    Bolt from the turbocharger mount on the engine
     
    Turbocharger return hose
     
    Oil pipe from the turbocharger to the oil filter adapter
     
    Bypass pipe and valve
     
    Exhaust manifold heat shield
     
    Radiator fan electrical connectors
     
    Upper radiator hose
     
    Radiator fan
     
    Boost pressure control valve connector
     
    Mass Air Flow (MAF) sensor connector
     
    Crankcase breather pipe
     
    MAF sensor and air hose
     
    Turbocharger to diaphragm hoses
     
    Quick release coupling on the vent hose
     
    Intake manifold V-clamp at the turbocharger
     
    Intake pipe from the steering pump mounting
     
    Intake pipe
     
    Hose between the turbocharger and charge air cooler
     
    Front exhaust system from the turbocharger
     
    Oil pipe from the turbocharger
     
    Water pipe from the turbocharger
     
    Water return pipes
     
    Bolts connecting the turbocharger to the exhaust manifold and loosen the V-belt
     
    Belt away from the power steering pump
     
    Power steering pump bracket and move the pump aside
     
    Exhaust manifold while saving the spacer sleeves and washers. Discard the gasket.
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    Fill the turbo inlet with oil. Rotate the compressor wheel by hand several times to assure the bearings are well lubricated.



    Exhaust manifold with a new gasket and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Power steering pump bracket. Torque the upper left mounting bolt to 18 ft. lbs. (24 Nm) first then torque the remaining bolts to the same specification.
     
    V-belt and tighten it with the tensioner
     



    Turbocharger to the exhaust manifold and torque the lock nuts to 18 ft. lbs. (24 Nm) and the studs to 16 ft. lbs. (22 Nm)
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm) Water return pipe with new copper washers and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Water pipe. Torque the turbo bolt to 19 ft. lbs. (25 Nm) and the water pump bolt to 15 ft. lbs. (20 Nm).
     
    Turbocharger intake pipe with a new lubricated O-ring to the power steering pump bracket. Torque the bolt and adjusting screw to 18 ft. lbs. (24 Nm).
     
    Hoses to the diaphragm and turbocharger
     
    Charge air cooler intake pipe to the turbocharger and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Exhaust manifold heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fan assembly
     
    Upper radiator hose
     
    MAF sensor and air hose
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    MAF sensor and boost pressure control valve connectors
     
    Bypass pipe and valve with a new lubricated O-ring
     
    Oil return hose
     
    Oil pipe to the oil filter adapter and torque the bolt to 19 ft. lbs. (25 Nm)
     
    Turbocharger mount and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Lower front cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

9-5 Models-3.0L Engine-Front
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Upper engine cover
     
    Turbocharger bypass pipe and valve
     
    Temperature/pressure sensor connector
     
    Turbocharger delivery pipe from the throttle body
     
    Turbocharger delivery pipe from the charge air cooler
     
    Exhaust manifold heat shield
     
    Secondary Air Injection (SAI) pipe and valve
     
    Crankcase ventilation pipe
     
    Turbocharger intake pipe
     
    Turbocharger outlet hose
     
    Fan motor wiring
     
    Radiator fan
     
    Turbocharger water pipes
     
    Dipstick tube
     
    Front pipe from the turbocharger
     
    Front exhaust pipe
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Oil pipe from the oil filter adapter
     
    Front exhaust manifold with the turbocharger and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.

    Click image to see an enlarged view

    Fig. Remove the exhaust manifold and turbocharger as an assembly-3.0L engine

  6.  

To install:

  1. Install or connect the following:

    Front exhaust manifold assembly with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front exhaust pipe with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Oil pipe to the oil filter adapter and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger oil return pipe and torque the bolt to 10 ft. lbs. (15 Nm)
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Dipstick tube
     
    Turbocharger water return pipe and torque the banjo bolt to 18 ft. lbs. (25 Nm) and the retaining screw to 10 ft. lbs. (15 Nm)
     
    Radiator and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Radiator fan wiring
     
    Turbocharger-to-charge air cooler hose and torque to 6 ft. lbs. (8 Nm)
     
    Turbocharger intake pipe and torque to 10 ft. lbs. (15 Nm)
     
    Crankcase ventilation pipe
     
    SAI pipe and valve
     
    Turbocharger delivery pipe to the throttle body and charge air cooler
     
    Temperature/pressure sensor connector
     
    Exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger by pass pipe and valve and torque to 6 ft. lbs. (8 Nm)
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

9-5 Models-Rear
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Upper engine cover
     
    Air inlet to the alternator
     
    Secondary Air Injection (SAI) pipe and valve
     
    Outer nuts from the rear exhaust manifold
     
    Front exhaust pipe
     
    Lower nuts from the rear exhaust manifold
     
    Upper nuts from the rear exhaust manifold
     
    Rear exhaust manifold and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Rear exhaust manifold with a new gasket and torque all the bolts to 15 ft. lbs. (20 Nm)
     
    Front exhaust pipe and torque the turbocharger locknuts to 18 ft. lbs. (25 Nm) and rear exhaust manifold bolts to 30 ft. lbs. (40 Nm)
     
    SAI pipe and valve
     
    Air intake to the alternator
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

900 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O 2 S) sensor connector
     
    Front pipe from exhaust manifold
     

  4.  
  5. Using a 3 / 8 inch ratchet extension, relieve the drive belt tensioner and remove the belt.

    Power steering pump pulley
     
    Power steering pump bracket
     

  6.  
  7. Move the pump to one side without disconnecting the hoses.
  8.  
  9. Remove the middle part of the exhaust manifold first, then remove the outer tubes.
  10.  

To install:

  1. Fit the outer tubes first, then mount middle part of exhaust manifold. Tighten the nuts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install or connect the following:

    Power steering pump bracket
     
    Power steering pump and pulley
     
    Drive belt
     
    Front pipe to the exhaust manifold
     
    O 2 S electrical connector
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

9000 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Center air deflector
     
    Top pipe coupling on the air-cooled oil cooler
     
    Clips securing the top pipe to the radiator
     
    Solenoid valve from its mounting on the radiator
     
    Radiator fan
     
    Oxygen (O 2 S) sensor cable clamps
     
    Exhaust pipe from the turbocharger. Bend it down slightly.
     
    Air mass meter
     
    Air cleaner cover
     
    Turbocharger pressure pipe from the compressor
     
    Oil pipe to the turbocharger unit
     
    Clip securing the oil pipe to the cylinder head
     
    Oil pipe banjo coupling from the block
     
    Clip on the intake manifold
     
    Coolant pipes from the turbocharger unit
     
    Steady bar bracket between the engine block and the turbocharger compressor
     
    Oil return lines. Cap the opening to prevent washers or nuts from the exhaust manifold dropping inside during removal.
     
    Turbocharger unit from the exhaust manifold
     
    A/C drive belt. Insert a sheet of metal to protect the oil cooler.
     
    A/C compressor mounting bolts. Lift the air conditioning compressor towards the expansion tank.
     
    Exhaust manifold complete with gasket
     

  6.  

To install:

  1. Clean all mating surfaces
  2.  
  3. Install or connect the following:
    WARNING
    Fill turbocharger interchamber passage with engine oil. It is very important that there is oil in the turbocharger when the engine is started to avoid damage to the unit.



    Exhaust manifold gasket and manifold and torque the nuts to 19 ft. lbs. (25 Nm)
     
    A/C compressor and belt, remove the locking tool and check for proper belt tension
     
    Turbocharger to the exhaust manifold and torque the new nuts to 16 ft. lbs. (22 Nm)
     



    Clip holding the turbocharger oil supply pipe to the intake manifold
     
    Banjo coupling to the engine block. Be sure the copper washers are in good condition.
     
    Pipe to the turbocharger unit
     
    Return oil pipe and the steady bar bracket between the turbocharger unit and the crankcase
     
    Rubber hangers for the front exhaust hanger
     
    Exhaust pipe to the turbocharger compressor with new locknuts. Lubricate the 3 studs on the turbocharger with Molykote 1000®. Torque the nuts to 19 ft. lbs. (25 Nm).
     
    Coolant pipes to the turbocharger unit
     
    Turbocharger pressure pipe to the turbocharger compressor
     
    Air mass meter
     
    Air cleaner assembly
     
    Radiator fan and solenoid valve
     
    Return hose to the solenoid valve
     
    A/C compressor
     
    Oil pipe to the oil cooler
     
    Center air deflector
     
    Negative battery cable
     

  4.  
  5. Properly fill the cooling system and check the oil level and quality.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

2.8L Engine
Front
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Fan cowling
     
    Intake manifold of secondary air injection pump from pump
     
    Discharge pipe of secondary air injection pump from pump
     
    Intake air sensor connector (688)
     
    Turbocharger delivery pipe
     
    Dipstick tube
     
    Front exhaust manifold heat shield
     
    Intermediate exhaust pipe from turbocharger and front exhaust manifold
     
    Secondary air pipe bolts to raise it slightly
     

  6.  
  7. Lubricate the studs and nuts with rust removal oil and carefully loosen.
  8.  
  9. Remove the exhaust manifold.
  10.  

To install:

  1. Clean the contact surfaces from gasket residue and soot.
  2.  
  3. Install the exhaust manifold using new bolts and a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the secondary air pipe using a new gasket and tighten the bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Connect the intermediate exhaust pipe to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with 90 513 210 Universal paste. Install all nuts.
    NOTE
    The conical side of the nut should face the center exhaust pipe.

  8.  
  9. Tighten the mounting nuts first on the exhaust manifold and then on the turbocharger to 22 ft. lbs. (30 Nm). Tighten in an alternating fashion on the turbocharger. The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the center exhaust pipe and/or exhaust manifold must be replaced.
  10.  
  11. Install or connect the following:

    Front exhaust manifold heat shield. Tighten fasteners to 7 ft. lbs. (10 Nm).
     
    Dipstick tube with new O-rings
     
    Turbocharger delivery pipe
     
    Intake air sensor connector (688)
     
    Discharge pipe of secondary air injection pump to the pump
     
    Intake manifold of secondary air injection pump to the pump
     
    Fan cowling
     

  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine, check for leaks and repair if necessary.
  16.  

Rear
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Front catalytic converter (B284E)
     
    Drive belt
     
    Alternator
     

  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the exhaust manifold heat shield.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the intermediate exhaust pipe.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Detach the rear secondary air pipe between the exhaust manifold and the check valve.
  18.  
  19. Remove the exhaust manifold.
  20.  

To install:

  1. Clean the contact surfaces from gasket residue and soot.
  2.  
  3. Install new gaskets. Coat the studs with 90 513 210 Universal paste.
  4.  
  5. Install the exhaust manifold using new bolts and a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Attach the rear secondary air pipe between the exhaust manifold and the check valve.
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the intermediate exhaust pipe to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with 90 513 210 Universal paste. Install all nuts.
    NOTE
    The conical side of the nut should face the center exhaust pipe.

  12.  
  13. Tighten the mounting nuts first on the exhaust manifold and then on the turbocharger to 22 ft. lbs. (30 Nm). Tighten in an alternating fashion on the turbocharger. The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the center exhaust pipe and/or exhaust manifold must be replaced.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Install the exhaust manifold heat shield. Tighten fasteners to 7 ft. lbs. (10 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Fit the generator to the bracket.
  22.  
  23. Install the drive belt.
  24.  
  25. Install the front catalytic converter (B284E).
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine, check for leaks and repair if necessary.
  30.  

3.0L Engines
Front Manifold
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Upper engine coverTurbocharger bypass pipe and valveTemperature/pressure sensor connectorTurbocharger delivery pipe from the throttle bodyTurbocharger delivery pipe from the charge air cooler (plug charge air opening)Exhaust manifold heat shieldSAI valve hose and nut on valve bracketBattery and vent hoseFront SAI pipe bolt and pipe from exhaust manifoldCrankcase ventilation pipe (between turbo inlet pipe and cylinder head)Oil trap hoseTurbocharger intake pipeTurbocharger outlet hose from charge air coolerFan motor connectorsRadiator fanPinch off inlet and return water hoses to turbochargerTurbocharger water pipesDipstick tubeFront pipe from the turbochargerOxygen sensor connectors (cut cable ties, note routing of sensor wiring)Separate pipe joint between front and rear exhaust systemsFront pipe from rear exhaust manifold (lower pipe away from front exhaust)Turbocharger oil return pipeTurbocharger mounting bracketOil pipe from the oil filter adapterFront exhaust manifold with the turbocharger and discard the gasket

    Upper engine cover
     
    Turbocharger bypass pipe and valve
     
    Temperature/pressure sensor connector
     
    Turbocharger delivery pipe from the throttle body
     
    Turbocharger delivery pipe from the charge air cooler (plug charge air opening)
     
    Exhaust manifold heat shield
     
    SAI valve hose and nut on valve bracket
     
    Battery and vent hose
     
    Front SAI pipe bolt and pipe from exhaust manifold
     
    Crankcase ventilation pipe (between turbo inlet pipe and cylinder head)
     
    Oil trap hose
     
    Turbocharger intake pipe
     
    Turbocharger outlet hose from charge air cooler
     
    Fan motor connectors
     
    Radiator fan
     
    Pinch off inlet and return water hoses to turbocharger
     
    Turbocharger water pipes
     
    Dipstick tube
     
    Front pipe from the turbocharger
     
    Oxygen sensor connectors (cut cable ties, note routing of sensor wiring)
     
    Separate pipe joint between front and rear exhaust systems
     
    Front pipe from rear exhaust manifold (lower pipe away from front exhaust)
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Oil pipe from the oil filter adapter
     
    Front exhaust manifold with the turbocharger and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following: Front exhaust manifold assembly with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Front exhaust pipe to rear exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)Pipe joint between front and rear exhaust systems; torque to 16 ft. lbs. (22 Nm)Secure oxygen sensor wiring with cable ties (note original routing of wiring)Oil pipe to the oil filter adapter and torque the fastener to 15 ft. lbs. (20 Nm)Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (25 Nm)Turbocharger oil return pipe and torque the bolt to 10 ft. lbs. (15 Nm)Oxygen sensor connectorFront exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (25 Nm)Dipstick tubeTurbocharger water return pipe and torque the banjo bolt to 18 ft. lbs. (25 Nm) and the retaining screw to 10 ft. lbs. (15 Nm)Remove pinching pliers from turbocharger water hosesRadiator fan; torque the bolts to 6 ft. lbs. (8 Nm)Radiator fan connectorsTurbocharger-to-charge air cooler hose and torque to 6 ft. lbs. (8 Nm)Turbocharger intake pipe and torque U-clamp to 2 ft. lbs. (3 Nm) and V-clamp to 10 ft. lbs. (15 Nm)MAF sensorCrankcase ventilation pipe (between cylinder head and turbo inlet pipe)Oil trap hoseSAI pipe and valveTurbocharger delivery pipe to the throttle body and charge air coolerTurbocharger delivery pipe to charge air cooler and throttle bodyTemperature/pressure sensor connectorExhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)Turbocharger by pass pipe and valve and torque to 6 ft. lbs. (8 Nm)Battery and vent hoseUpper engine coverNegative battery cable

    Front exhaust manifold assembly with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front exhaust pipe to rear exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Pipe joint between front and rear exhaust systems; torque to 16 ft. lbs. (22 Nm)
     
    Secure oxygen sensor wiring with cable ties (note original routing of wiring)
     
    Oil pipe to the oil filter adapter and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger oil return pipe and torque the bolt to 10 ft. lbs. (15 Nm)
     
    Oxygen sensor connector
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Dipstick tube
     
    Turbocharger water return pipe and torque the banjo bolt to 18 ft. lbs. (25 Nm) and the retaining screw to 10 ft. lbs. (15 Nm)
     
    Remove pinching pliers from turbocharger water hoses
     
    Radiator fan; torque the bolts to 6 ft. lbs. (8 Nm)
     
    Radiator fan connectors
     
    Turbocharger-to-charge air cooler hose and torque to 6 ft. lbs. (8 Nm)
     
    Turbocharger intake pipe and torque U-clamp to 2 ft. lbs. (3 Nm) and V-clamp to 10 ft. lbs. (15 Nm)
     
    MAF sensor
     
    Crankcase ventilation pipe (between cylinder head and turbo inlet pipe)
     
    Oil trap hose
     
    SAI pipe and valve
     
    Turbocharger delivery pipe to the throttle body and charge air cooler
     
    Turbocharger delivery pipe to charge air cooler and throttle body
     
    Temperature/pressure sensor connector
     
    Exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger by pass pipe and valve and torque to 6 ft. lbs. (8 Nm)
     
    Battery and vent hose
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Upper engine coverTurbocharger bypass pipe and valveTemperature/pressure sensor connectorTurbocharger delivery pipe from the throttle bodyTurbocharger delivery pipe from the charge air cooler (plug charge air opening)Exhaust manifold heat shieldSAI valve hose and nut on valve bracketBattery and vent hoseFront SAI pipe bolt and pipe from exhaust manifoldCrankcase ventilation pipe (between turbo inlet pipe and cylinder head)Oil trap hoseTurbocharger intake pipeTurbocharger outlet hose from charge air coolerFan motor connectorsRadiator fanPinch off inlet and return water hoses to turbochargerTurbocharger water pipesDipstick tubeFront pipe from the turbochargerOxygen sensor connectors (cut cable ties, note routing of sensor wiring)Separate pipe joint between front and rear exhaust systemsFront pipe from rear exhaust manifold (lower pipe away from front exhaust)Turbocharger oil return pipeTurbocharger mounting bracketOil pipe from the oil filter adapterFront exhaust manifold with the turbocharger and discard the gasket

    Upper engine cover
     
    Turbocharger bypass pipe and valve
     
    Temperature/pressure sensor connector
     
    Turbocharger delivery pipe from the throttle body
     
    Turbocharger delivery pipe from the charge air cooler (plug charge air opening)
     
    Exhaust manifold heat shield
     
    SAI valve hose and nut on valve bracket
     
    Battery and vent hose
     
    Front SAI pipe bolt and pipe from exhaust manifold
     
    Crankcase ventilation pipe (between turbo inlet pipe and cylinder head)
     
    Oil trap hose
     
    Turbocharger intake pipe
     
    Turbocharger outlet hose from charge air cooler
     
    Fan motor connectors
     
    Radiator fan
     
    Pinch off inlet and return water hoses to turbocharger
     
    Turbocharger water pipes
     
    Dipstick tube
     
    Front pipe from the turbocharger
     
    Oxygen sensor connectors (cut cable ties, note routing of sensor wiring)
     
    Separate pipe joint between front and rear exhaust systems
     
    Front pipe from rear exhaust manifold (lower pipe away from front exhaust)
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Oil pipe from the oil filter adapter
     
    Front exhaust manifold with the turbocharger and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following: Front exhaust manifold assembly with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Front exhaust pipe to rear exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)Pipe joint between front and rear exhaust systems; torque to 16 ft. lbs. (22 Nm)Secure oxygen sensor wiring with cable ties (note original routing of wiring)Oil pipe to the oil filter adapter and torque the fastener to 15 ft. lbs. (20 Nm)Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (25 Nm)Turbocharger oil return pipe and torque the bolt to 10 ft. lbs. (15 Nm)Oxygen sensor connectorFront exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (25 Nm)Dipstick tubeTurbocharger water return pipe and torque the banjo bolt to 18 ft. lbs. (25 Nm) and the retaining screw to 10 ft. lbs. (15 Nm)Remove pinching pliers from turbocharger water hosesRadiator fan; torque the bolts to 72 inch lbs. (8 Nm)Radiator fan connectorsTurbocharger-to-charge air cooler hose and torque to 6 ft. lbs. (8 Nm)Turbocharger intake pipe and torque U-clamp to 24 inch lbs. (3 Nm) and V-clamp to 10 ft. lbs. (15 Nm)MAF sensorCrankcase ventilation pipe (between cylinder head and turbo inlet pipe)Oil trap hoseSAI pipe and valveTurbocharger delivery pipe to the throttle body and charge air coolerTurbocharger delivery pipe to charge air cooler and throttle bodyTemperature/pressure sensor connectorExhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)Turbocharger by pass pipe and valve and torque to 72 inch lbs. (8 Nm)Battery and vent hoseUpper engine coverNegative battery cable

    Front exhaust manifold assembly with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front exhaust pipe to rear exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Pipe joint between front and rear exhaust systems; torque to 16 ft. lbs. (22 Nm)
     
    Secure oxygen sensor wiring with cable ties (note original routing of wiring)
     
    Oil pipe to the oil filter adapter and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger oil return pipe and torque the bolt to 10 ft. lbs. (15 Nm)
     
    Oxygen sensor connector
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Dipstick tube
     
    Turbocharger water return pipe and torque the banjo bolt to 18 ft. lbs. (25 Nm) and the retaining screw to 10 ft. lbs. (15 Nm)
     
    Remove pinching pliers from turbocharger water hoses
     
    Radiator fan; torque the bolts to 72 inch lbs. (8 Nm)
     
    Radiator fan connectors
     
    Turbocharger-to-charge air cooler hose and torque to 6 ft. lbs. (8 Nm)
     
    Turbocharger intake pipe and torque U-clamp to 24 inch lbs. (3 Nm) and V-clamp to 10 ft. lbs. (15 Nm)
     
    MAF sensor
     
    Crankcase ventilation pipe (between cylinder head and turbo inlet pipe)
     
    Oil trap hose
     
    SAI pipe and valve
     
    Turbocharger delivery pipe to the throttle body and charge air cooler
     
    Turbocharger delivery pipe to charge air cooler and throttle body
     
    Temperature/pressure sensor connector
     
    Exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger by pass pipe and valve and torque to 72 inch lbs. (8 Nm)
     
    Battery and vent hose
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Upper engine cover
     
    Turbocharger bypass pipe and valve
     
    Temperature/pressure sensor connector
     
    Turbocharger delivery pipe from the throttle body
     
    Turbocharger delivery pipe from the charge air cooler (plug charge air opening)
     
    Exhaust manifold heat shield
     
    SAI valve hose and nut on valve bracket
     
    Battery and vent hose
     
    Front SAI pipe bolt and pipe from exhaust manifold
     
    Crankcase ventilation pipe (between turbo inlet pipe and cylinder head)
     
    Oil trap hose
     
    Turbocharger intake pipe
     
    Turbocharger outlet hose from charge air cooler
     
    Fan motor connectors
     
    Radiator fan
     
    Pinch off inlet and return water hoses to turbocharger
     
    Turbocharger water pipes
     
    Dipstick tube
     
    Front pipe from the turbocharger
     
    Oxygen sensor connectors (cut cable ties, note routing of sensor wiring)
     
    Separate pipe joint between front and rear exhaust systems
     
    Front pipe from rear exhaust manifold (lower pipe away from front exhaust)
     
    Turbocharger oil return pipe
     
    Turbocharger mounting bracket
     
    Oil pipe from the oil filter adapter
     
    Front exhaust manifold with the turbocharger and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Front exhaust manifold assembly with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front exhaust pipe to rear exhaust manifold with a new gasket and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Pipe joint between front and rear exhaust systems; torque to 16 ft. lbs. (22 Nm)
     
    Secure oxygen sensor wiring with cable ties (note original routing of wiring)
     
    Oil pipe to the oil filter adapter and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Turbocharger mounting bracket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger oil return pipe and torque the bolt to 10 ft. lbs. (15 Nm)
     
    Oxygen sensor connector
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Dipstick tube
     
    Turbocharger water return pipe and torque the banjo bolt to 18 ft. lbs. (25 Nm) and the retaining screw to 10 ft. lbs. (15 Nm)
     
    Remove pinching pliers from turbocharger water hoses
     
    Radiator fan; torque the bolts to 72 inch lbs. (8 Nm)
     
    Radiator fan connectors
     
    Turbocharger-to-charge air cooler hose and torque to 6 ft. lbs. (8 Nm)
     
    Turbocharger intake pipe and torque U-clamp to 24 inch lbs. (3 Nm) and V-clamp to 10 ft. lbs. (15 Nm)
     
    MAF sensor
     
    Crankcase ventilation pipe (between cylinder head and turbo inlet pipe)
     
    Oil trap hose
     
    SAI pipe and valve
     
    Turbocharger delivery pipe to the throttle body and charge air cooler
     
    Turbocharger delivery pipe to charge air cooler and throttle body
     
    Temperature/pressure sensor connector
     
    Exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Turbocharger by pass pipe and valve and torque to 72 inch lbs. (8 Nm)
     
    Battery and vent hose
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

Rear Manifold
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableUpper engine coverAir intake to alternatorOxygen sensor connectors from holder on rear SAI valveSAI pipe from cylinder head and connections from exhaust manifoldSAI valve and pipeOuter nuts from the rear exhaust manifoldFront exhaust pipe from rear exhaust2 lower nuts from the rear exhaust manifold3 upper nuts from the rear exhaust manifoldRear exhaust manifold and discard the gasket

    Negative battery cable
     
    Upper engine cover
     
    Air intake to alternator
     
    Oxygen sensor connectors from holder on rear SAI valve
     
    SAI pipe from cylinder head and connections from exhaust manifold
     
    SAI valve and pipe
     
    Outer nuts from the rear exhaust manifold
     
    Front exhaust pipe from rear exhaust
     
    2 lower nuts from the rear exhaust manifold
     
    3 upper nuts from the rear exhaust manifold
     
    Rear exhaust manifold and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following: Rear exhaust manifold with a new gasket and torque all the bolts to 15 ft. lbs. (20 Nm)Front exhaust pipe and torque the turbocharger locknuts to 18 ft. lbs. (25 Nm) and rear exhaust manifold bolts to 30 ft. lbs. (40 Nm)SAI pipe and valveOxygen sensor connectors to SAI holderAir intake to the alternatorUpper engine coverNegative battery cable

    Rear exhaust manifold with a new gasket and torque all the bolts to 15 ft. lbs. (20 Nm)
     
    Front exhaust pipe and torque the turbocharger locknuts to 18 ft. lbs. (25 Nm) and rear exhaust manifold bolts to 30 ft. lbs. (40 Nm)
     
    SAI pipe and valve
     
    Oxygen sensor connectors to SAI holder
     
    Air intake to the alternator
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Upper engine cover
     
    Air intake to alternator
     
    Oxygen sensor connectors from holder on rear SAI valve
     
    SAI pipe from cylinder head and connections from exhaust manifold
     
    SAI valve and pipe
     
    Outer nuts from the rear exhaust manifold
     
    Front exhaust pipe from rear exhaust
     
    2 lower nuts from the rear exhaust manifold
     
    3 upper nuts from the rear exhaust manifold
     
    Rear exhaust manifold and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Rear exhaust manifold with a new gasket and torque all the bolts to 15 ft. lbs. (20 Nm)
     
    Front exhaust pipe and torque the turbocharger locknuts to 18 ft. lbs. (25 Nm) and rear exhaust manifold bolts to 30 ft. lbs. (40 Nm)
     
    SAI pipe and valve
     
    Oxygen sensor connectors to SAI holder
     
    Air intake to the alternator
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

 
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