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(13) Disconnect articulated exhaust pipe joint from turbocharger housing. (14) Remove turbocharger coolant inlet line assem- bly from engine (Fig. 11). (15) Lift turbocharger off manifold mounting studs and lower assembly down and out of vehicle. EXHAUST MANIFOLD REMOVAL Remove 9 exhaust manifold retaining fasteners and remove exhaust manifold (Fig. 14). CLEANING AND INSPECTION (1) Discard gasket and clean all gasket surfaces of manifolds and cylinder head. (2) Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm (3) Inspect manifolds for cracks or distortion. Re- place manifold if necessary. EXHAUST MANIFOLD INSTALLATION (1) Install new manifold gasket. DO NOT APPLY SEALER. (2) Set exhaust manifold in place. Tighten retain- ing nuts and bolt, starting at center and progressing Im (200 in. lbs.) torque. Repeat this procedure until all fasteners are TURBOCHARGER INSTALLATION (1) Position turbocharger on exhaust manifold. Ap- ply antiseize compound to threads and install the (passenger side) retaining nut (Fig. 12). Tighten nut to 54 N Im (40 ft. lbs.) torque. (2) Apply thread sealant to lower (inlet) coolant line fitting and install fitting into turbocharger hous- (3) Install lower coolant line assembly to engine (Fig. 11). (4) Install oil drain back tube and fitting (with new gasket) to turbocharger housing (Fig. 13). (5) Install turbocharger to block support bracket and install screws finger tight (Fig. 13). Tighten Im (40 ft. lbs.) torque, then tighten screw to turbocharger housing to 27 Im (20 ft. lbs.) torque. (6) Reposition exhaust pipe. Tighten articulated joint shoulder bolts to 28 N Im (250 in. lbs.) torque. (7) See Suspension, Group 2, and install right driveshaft and wheel and tire assembly. Install air (8) From Above: Install three turbocharger to manifold retaining nuts. Tighten to 54 N Im (40 ft. lbs.) torque (Fig. 12). (9) Reconnect Heated Oxygen sensor electrical con- nection and vacuum lines. (10) Attach oil feed line to turbocharger bearing housing. Tighten fitting to 14 N Im (125 in. lbs.) torque (Fig. 12). (11) Install coolant line and tighten fittings to 41 N Im (30 ft. lbs.) torque (Fig. 11). (12) Install air cleaner support (Fig. 1). bracket. Install through bolt and tighten to 54 N Im (40 ft. lbs.) torque. (14) Install air cleaner assembly (Fig. 1). Group 7 for procedure. INTAKE/EXHAUST MANIFOLD SERVICE—3.0L The intake system has a large air intake plenum of aluminum alloy and a cross type intake manifold Fig. 13 Oil Return Tube and Support Bracket Fig. 14 Exhaust Manifold—Turbo III Engine Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13 |