EXJ_11A99 jeep xj service manual

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    EXHAUST SYSTEM AND TURBOCHARGER

    CONTENTS

    page page

    GENERAL INFORM ATIONEXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . . 1

    EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1

    REMOVAL AND INSTALLATIONEXHAUST MANIFOLD AND TURBOCHARGER

    (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    EXHAUST MANIFOLD AND TURBOCHARGER

    (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

    EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2

    INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 10

    MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 2

    SPECIFICATIONSTORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 10

    GENERAL INFORMATION

    EXHAUST SYSTEMTh e b a s ic e xh a u s t s y st e m con s is t s of a n e ng in e

    exh a us t m a ni fold , exh a us t pipe, exh a us t h ea t

    shield(s), muffler and exhaust tai lpipe.

    The exhaust system uses a single muffler.

    Th e e xh a u s t s y s t em m u s t be p r op er l y a l i g n ed t o

    p r e v e n t s t r e s s , l e a k a g e a n d bo d y c o n t a c t . I f t h e s y s -

    t e m con t a c t s a n y bod y p a n e l, i t m a y a m p l if y obje c-

    tionable noises originating from the engine or body.

    Wh en i n sp ect i n g a n ex h a u st s y st e m, cr it i ca l l y

    inspect for cracked or loose joints, stripped screw or

    bolt threads, corrosion damage and worn, cracked or

    b r ok en h a n g er s . R ep la c e a l l com pon en t s t h a t a r e

    b a d ly cor r od ed or d a m a g ed . D O N OT a t t em pt t o

    repair.

    When replacement is required, use original equip-

    m e n t p a r t s (or e q u iv a l e n t ). Th i s w i l l a s s u r e p r op er

    alignment and provide acceptable exhaust noise lev-

    els.

    CAUTION: Avoid application of rust preventioncompounds or undercoating materials to exhaustsystem floor pan exhaust heat shields. Light over-spray near the edges is permitted. Application of

    coating will result in excessive floor pan tempera-tures and objectionable fumes.

    EXHAUST HEAT SHIELDSE x h a u st h ea t s h ie ld s a r e n eed ed t o p rot e ct b ot h

    t h e v e h i c l e a n d t h e e n v i r o n m e n t f r o m t h e h i g h t e m -

    peratures (Fig. 1).

    DO NOT allow the engine to operate at fast idle for

    extended periods (over 5 minutes). This condition

    may result in excessive temperatures in the exhaust

    s y s t e m a n d o n t h e f l o o r p a n .

    Fig. 1 Heat Shields

    XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 1

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    REMOVAL AND INSTALLATION

    EXHAUST PIPE

    WARNING: IF TORCHES ARE USED WHEN WORK-ING ON THE EXHAUST SYSTEM, DO NOT ALLOW

    THE FLAME NEAR THE FUEL LINES.

    REMOVAL(1) Raise and support the vehicle.

    (2 ) Sa t u r a t e t h e bo l t s a n d n u t s a t t u r bo d o w n p i p e

    t o e xh a u s t p ip e w i t h h ea t v a l ve l ub r ica n t . Al low 5

    minutes for penetration.

    (3) Di s con n e ct bol t s f r om e xh a u s t p ip e t o t u r bo

    down pipe (Fig. 2).

    (4) Remove t he clamp nuts at muffler (Fig. 3). To

    remove the exha ust pipe from th e muffler, apply hea t

    u n t i l t h e m e t a l becom e s c h er r y r e d . D i s con n e ct t h e

    e xh a u s t p ip e f r o m t h e m u f fl er. R em ov e t h e e xh a u s t

    pipe.

    INSTALLATION(1) A ss em ble e xh a u s t p ip e t o m u f fl er, l oos el y t o

    permit proper al ignment of al l parts.

    (2) C o n ne ct t h e e xh a u s t p ip e t o t h e t u r bo d ow n

    pipe manifold. Tighten the bolts to 22.5 Nm torque.

    (3) U s e a n ew cl a mp a n d t i gh t en t h e n u t s t o 4 3

    Nm torque.(4) Lower the vehicle.

    (5 ) St a r t t h e e n g i n e a n d i n s p e c t f o r e x h a u s t l e a k s

    a n d e xh a u s t s y st e m con t a c t w i t h t h e b od y p a n el s.

    Adjust the al ignment, i f needed.

    MUFFLER AND EXHAUST TAILPIPEAll original equipment exhaust systems are manu-

    f a c t u r ed w i t h t h e e x h a u s t t a i l p ip e w e l d ed t o t h e m u f -

    f ler. S er vi ce r ep la cem en t m uf fl er s a n d exh a u st

    t a i l pi pe s a r e e it h e r cl a m pe d t og et h e r or w e ld ed

    together.

    WARNING: IF TORCHES ARE USED WHEN WORK-ING ON THE EXHAUST SYSTEM, DO NOT ALLOWTHE FLAME NEAR THE FUEL LINES.

    REMOVAL(1) Raise and support the vehicle.

    (2) R em ov e t h e f ron t m u ff ler cl a mp f rom t h e

    exhaust pipe and muffler connection.

    (3) Remove the rear exhaust tai lpipe hanger clamp

    a n d r em ov e t h e exh a u st t a i lpi pe f rom t h e f ron t

    exhaust tai lpipe hanger.

    (4) Remove the exhaust tai lpipe assembly from the

    muffler.

    INSTALLATION(1) I n st a l l t h e m uf fl er on t o t h e ex ha u st pi pe.

    I n s t a l l t h e c l a m p a n d t i g h t e n t h e n u t s f i n g e r t i g h t .

    (2) I n s t a l l t h e e xh a u s t t a i lp ip e i n t o t h e r e a r of t h e

    muffler.

    (3) Insta l l the exha ust ta i lpipe/muffler assembly

    o n t h e r e a r e x h a u s t t a i l p i p e h a n g e r . M a k e s u r e t h a t

    the exhaust tai lpipe has sufficient clearance from the

    floor pan.

    (4) I n st a l l t h e r em a i ni ng cl a mp s a n d t h e f ron t

    exhaust tai lpipe hanger.

    (5) Tighten the nuts on the muffler-to-exhaust pipe

    clamp to 43 Nm torque.

    (6) Tighten the nuts on the muffler-to-exhaust pipe

    clamp to 43 Nm torque.

    (7) Lower the vehicle.

    (8 ) St a r t t h e e n g i n e a n d i n s p e c t f o r e x h a u s t l e a k s

    a n d e xh a u s t s y st e m con t a c t w i t h t h e b od y p a n el s.

    Adjust the al ignment, i f needed.

    Fig. 2 Exhaust Down Pipe to Front Exhaust Pipe

    Fig. 3 Front Pipe to Muffler

    11 - 2 EXHAUST SYSTEM AND TURBOCHARGER XJ

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    EXHAUST MANIFOLD AND TURBOCHARGER(LHD)

    REMOVAL(1) Disconnect the negative battery cable.

    (2) Disconnect the breather hose from air cleaner

    outlet hose (Fig. 4).

    (3) Remove the air fi l ter cover and hose from tur-

    bocharger, remove the assembly (Fig. 4).

    (4) Remove the EGR vacuum supply hose from the

    E G R v a l ve .

    (5) Remove t he innercooler inlet an d outlet hoses

    from the engine (Fig. 4).

    (6 ) R e m o v e t h e (2 ) bo l t s h o l d i n g t h e E GR t u be t o

    t h e E G R v a l v e .

    (7) R e mov e t h e i n t a k e m a n i fol d e lb ow a n d E G R

    v a l v e a s a n a s s e m bl y .

    (8) Raise the vehicle on a hoist .

    (9) D r a i n t h e cool in g s y st e m. R ef er t o G r o up 7,

    Cooling System for procedure.

    (10) R em ov e t h e e xh a u s t s y s t em s u pp or t cl a m p(Fig. 5).

    (11) Disconnect the exhaust system at the (3) bolt

    flange (Fig. 5).

    CAUTION: Heatshield is very sharp. Wear gloves to

    prevent injury.

    (12) U n s t r a p t h e e xh a u s t d ow n p ip e h ea t s h i el d

    (Fig. 6).

    (13) D i s con n e ct t h e t u r boch a r g e r oi l r e t u r n h os e

    from the engine block (Fig. 7).

    (14) Lower the vehicle from the hoist .

    (15) Remove the EGR tube from exhaust manifold.

    (16) Remove the (2) exhaust man ifold heatshield

    r e t a i n i n g bol t s a n d r e m ov e t h e h e a t s h i el d .

    (17) Remove the heater core supply hoses from the

    vehicle.

    (18) R e mov e t h e oi l p r es s u re s u pp ly l in e ba n g o

    bolt from the turbocharger.

    Fig. 5 Exhaust System Inlet Pipe Connection

    Fig. 6 Exhaust Downpipe Heatshield

    Fig. 4 Engine Compartment

    XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 3

    REMOVAL AND INSTALLATION (Continued)

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    CAUTION: Heatshield is very sharp. Wear gloves toprevent injury.

    (19) R e m ov e t h e e xh a u s t d ow n p i pe h e a t s h i el d by

    pulling straight up.

    (20) Remove the (5) bolts from exha ust man ifold

    downpipe and remove pipe.

    (21) R em ov e t h e (8) e xh a u s t m a n i f ol d r e t a i n i n g

    bol t s , i t i s n e ce ss a r y t o a cce ss t h e bol t beh i n d t h e

    manifold outlet from the underneath of the vehicle.

    (22) R em ov e t h e exh a u st m a n if ol d a n d t u rb o-

    charger assembly from the vehicle.

    (23) P l a ce a s s em b ly i n a v ice t o r em ov e t h e (3)

    exhaust manifold to turbocharger retaining nuts (Fig.

    8).

    CleaningAll old gaskets should be inspected for any tears or

    signs of prior leakage. If any gaskets show such indi-

    ca t i o n s, t h e y s h ou l d be r e pl a c ed w i t h n e w g a s k et s .

    Al l g a s k et m a t i n g s u r fa c es m u s t be c l ea n e d of ol d

    g a s ke t m a t e r ia l t o p r od u ce a s m oot h a n d d ir t f r ees ea l i n g s u r f a c e f or t h e n e w g a s k et .

    INSTALLATION(1) Tr a n s f e r t h e oi l r e t u r n h os e t o t h e n e w t u r bo-

    charger (Fig. 9).

    (2) I n s t a l l t h e t u r bo on t h e e x h a u s t m a n i f ol d (Fi g.

    9). Torque t he n uts to 32 Nm (23 ft. lbs.).

    (3 ) I n s t a l l t h e e x h a u s t m a n i f o l d a n d t u r bo c h a r g e r

    assembly in the vehicle.

    (4) Instal l the (8) exhaust manifold retaining nuts.

    Torque n uts to 32 Nm (23 ft. lbs.).

    (5) Insta l l t he exhaust ma nifold downpipe. Torque

    bolts to 32 Nm (23 ft. lbs.).

    CAUTION: Heatshield is very sharp. Wear gloves toprevent injury.

    (6) Sl i d e t h e e xh a u s t d ow n p i pe h e a t s h i el d d ow n

    over pipe. Do not attempt to strap heatshield in posi-

    tion at this t ime, wait unti l vehicle is raised on hoist .

    Fig. 8 Turbocharger / Exhaust Manifold Assembly

    Fig. 9 Turbocharger / Exhaust Manifold Assembly

    Fig. 7 Turbocharger Oil Return Hose

    11 - 4 EXHAUST SYSTEM AND TURBOCHARGER XJ

    REMOVAL AND INSTALLATION (Continued)

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    (7) I n s t a l l t h e oi l p r es s u re s u pp ly l in e on t u r bo-

    charger. Torque bango bolt fi t t ing to 27 Nm (20 ft .

    lbs.).

    (8) Instal l the heater core supply hoses.

    (9) P o s it i on a n d i n s t a l l t h e e xh a u s t m a n i f ol d h e a t -

    shield. Torque bolts to 11 Nm (97 in. lbs.).

    (10) Raise the vehicle on a hoist .(11) Instal l the turbocharger oil return hose on the

    engine block (Fig. 10).

    (1 2 ) St r a p t h e e x h a u s t d o w n p i p e h e a t s h i e l d i n i t s

    original position.

    (13) C o n n ect t h e e xh a u s t s y s t em a t t h e (3) bo lt

    flange (Fig. 11). Torque the bolts to 23 Nm (17 ft .

    lbs.).

    (14) I n s t a l l t h e e xh a u s t s y st e m s u pp or t cl a m p

    (Fig. 11). Torque nut s to 23 Nm (17 ft. lbs.).

    (15) Lower the vehicle from the hoist .

    (16) I n s t a l l t h e i n t a k e m a n i f ol d e lb ow a n d E G R

    valve a s an assembly. Torque bolts to 27 Nm (20 ft .

    lbs.).

    (1 7 ) I n s t a l l t h e (2 ) bo l t s h o l d i n g t h e E GR t u be t o

    the EG R valve. Torque bolts to 27 Nm (20 ft . lbs.).(18) I nsta l l t he innercooler inlet an d outlet hoses

    on the engine (Fig. 12).

    (19) I n s t a l l t h e E G R v a c uu m s u pp ly h os e o n t h e

    E G R v a l ve .

    (2 0 ) I n s t a l l t h e a i r f i l t e r c o v e r a n d o u t l e t h o s e o n

    turbocharger (Fig. 12).

    (21) C o n n ect t h e br ea t h e r h os e o n t h e a i r cl ea n e r

    outlet hose (Fig. 12).

    (22) F i ll t h e cool in g s y st e m. R ef er t o G r o up 7,

    Cooling System for procedure.

    (23) Connect the negative battery cable

    (24) Start the engine and check for leaks.

    EXHAUST MANIFOLD AND TURBOCHARGER(RHD)

    REMOVAL(1) Disconnect the negative battery cable.

    (2) D i scon n ect t h e b r ea t h e r h os e f r om t h e a i r

    cleaner outlet hose.

    Fig. 10 Turbocharger Oil Return Hose

    Fig. 11 Exhaust System Inlet Pipe Connection

    Fig. 12 Engine Compartment

    XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 5

    REMOVAL AND INSTALLATION (Continued)

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    (3 ) R e m o v e t h e a i r f i l t e r c o v e r a n d t h e h o s e f r o m

    the turbocharger, remove the assembly.

    (4) Raise the vehicle on a hoist .

    (5) D r a i n t h e cool in g s y st e m. R ef er t o G r o up 7,

    Cooling System for the procedure.

    (6) R em ov e t h e e xh a u s t s y st e m s u pp or t cl a m p

    (Fig. 13).

    (7) Di s con n e ct t h e e xh a u s t s y s t em a t t h e (3) bo lt

    flange (Fig. 13).

    CAUTION: Heatshield is very sharp. Wear gloves toprevent injury.

    (8) Unstrap the exhaust downpipe heatshield (Fig.

    14).

    CAUTION: Heatshield is very sharp. Wear gloves toprevent injury.

    (9) R em ov e t h e e xh a u s t d ow n p i pe h e a t s h i el d by

    p u ll i n g s t r a i g h t d ow n .

    (10) D i s con n e ct t h e t u r boch a r g e r oi l r e t u r n h os e

    from the engine block (Fig. 15).

    (11) Lower the vehicle from the hoist .

    (12) Disconnect the heater core coolant supply and

    the brake vacuum supply hoses from the right side of

    t h e e n gi n e. R e m ov e t h e s t e el l i n e s u p por t br a c ke t

    f r om t h e t op of t h e r ock er cov er a n d p os it i on t h e

    a s s e m bl y o u t o f t h e w a y .

    (13) R e m ov e t h e E G R v a c uu m s u pp ly h os e f r om

    t h e E G R v a l v e .

    (14) Remove the innercooler inlet and outlet hoses

    from the engine.

    (15) Remove the (2) bolts holding the EGR tube to

    t h e E G R v a l ve .

    (16) R e mov e t h e i n t a k e m a n i fol d e lb ow a n d t h e

    E GR v a l v e a s a n a s s e m bl y .

    (17) R e mov e t h e E G R t u be f r om t h e e x h a u s t m a n -

    ifold.

    (18) Remove the (2) exhaust man ifold heatshield

    retaining bolts and remove the heatshield (Fig. 16).

    (19) Remove the oil pressure supply l ine from the

    turbocharger (Fig. 16).

    Fig. 14 Exhaust Downpipe Heatshield

    Fig. 15 Turbocharger Oil Return Hose

    Fig. 13 Exhaust System Inlet Pipe Connection

    11 - 6 EXHAUST SYSTEM AND TURBOCHARGER XJ

    REMOVAL AND INSTALLATION (Continued)

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    (20) Remove the clutch master cylinder heatshield

    (Fig. 16).

    (21) R e m ov e t h e w a s t e ga t e a c t u a t o r v a c uu m s u p-

    ply hose from the actuator (Fig. 17).

    (22) Remove the turbocha rger oil pressure supply

    line from the engine block (Fig. 17).

    (23) Wor k i n g i n s id e of t h e v eh i cl e, r e m ov e t h e

    Kn e e B l o c k e r . R e f e r t o Gr o u p 8 E , I n s t r u m e n t P a n e l

    Systems for the procedure.

    (24) Disconnect the neutral safety switch electrical

    connector at the clutch pedal .

    (25) Remove the (2) clutch master cylinder retain-

    i n g n u t s f r o m t h e bu l k h e a d .

    (26) Working from the inside of the engine com-

    p a r t m e n t , r e m ov e t h e cl u t ch m a s t e r cy l in d e r f r om

    t h e b ul kh ea d a n d pos it i on t h e cy li nd er a n d l in ea s s e m bl y o u t o f t h e w a y .

    (27) Remove t he (5) bolts from the exhaust man i-

    fold downpipe and remove the pipe.

    (28) R e mov e t h e (8) e xh a u s t m a n i f ol d r e t a i n i n g

    bol t s , i t i s n e ce ss a r y t o a cce ss t h e bol t beh i n d t h e

    manifold outlet from the underneath of the vehicle.

    (29) Remove the steering shaft pinchbolt and sl ide

    t h e s h a f t s t r a i g h t of f o f t h e g e a r box i n p u t s h a f t . P os i -

    tion aside.

    (30) R e mov e t h e e xh a u s t m a n i f ol d a n d t h e t u r bo-

    charger assembly from the vehicle.

    (31) P l a ce t h e t u r bo a s s em bly i n a v i ce t o r e m ov e

    t h e (3) e x h a u s t m a n i f ol d t o t u r boch a r g e r r e t a i n i n gnuts (Fig. 18).

    CleaningAll old gaskets should be inspected for any tears or

    signs of prior leakage. If any gasket shows such indi-

    ca t i on s , i t m u s t be r e pl a c ed w i t h a n e w g a s k et . Al l

    g a s k et m a t i n g s ur f a ce s m u s t b e c le a n ed of a l l ol d

    g a s k et m a t e r ia l t o p r od u ce a s m oot h a n d d ir t f r ee

    s ea l i n g s u r fa c e f or t h e n e w g a s k et .

    INSTALLATION(1 ) I n s t a l l t h e t u r bo c h a r g e r o n t h e e x h a u s t m a n i -

    fold (Fig. 19). Torque nut s to 32 Nm (23 ft. lbs.).

    Fig. 16 2.5L Turbo Diesel Heatshields

    Fig. 17 R.H.D. Turbo Position & Orientation

    Fig. 18 Turbocharger / Exhaust Manifold Assembly

    XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 7

    REMOVAL AND INSTALLATION (Continued)

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    (2 ) I n s t a l l t h e e x h a u s t m a n i f o l d a n d t u r bo c h a r g e r

    assembly in the vehicle.

    (3) Instal l the (8) exhaust manifold retaining nuts,

    i t is necessary to access the bolt behind the manifold

    ou t l et f r om t h e u n d er n e a t h of t h e v eh i cl e. Tor q u e

    nuts to 32 Nm (23 ft . lbs.).

    (4) In sta l l t he exha ust man ifold downpipe. Torque

    the bolts to 32 Nm (23 ft . lbs.).

    (5) P osition the turbocha rger oil pressure supply

    line in its original position (Fig. 20). Torque t he t urbo

    fi t t ing to 27 Nm (20 ft . lbs.).

    (6 ) I n s t a l l t h e w a s t e g a t e a c t u a t o r v a c u u m s u p p l y

    hose on the actuator (Fig. 20).

    (7) I n s t a l l t h e e xh a u s t m a n i f ol d h e a t s h i el d (Fi g .

    21). Torque bolts to 11 Nm (97 in. lbs.).

    (8 ) I n s t a l l t h e E GR t u be o n t h e e x h a u s t m a n i f o l d .

    L e a v e l oos e a t t h i s t i m e.(9) Raise the vehicle on a hoist .

    CAUTION: Heatshield is very sharp. Wear gloves toprevent injury.

    (10) S li d e t h e e xh a u s t d ow n p ip e h ea t s h i el d u p

    over the pipe and strap i t in i ts original position (Fig.

    22).

    (11) I n s t a l l t h e s t e er i n g s h a f t . Tor q u e t h e p in ch

    bolt to 49 Nm (36 ft. lbs.).

    (12) Instal l the turbocharger oil return hose on the

    engine block (Fig. 23).

    (13) C o n n ect t h e e xh a u s t s y s t em a t t h e (3) bo ltflange (Fig. 24). Torque the bolts to 23 Nm (17 ft .

    lbs.).

    (14) I n s t a l l t h e ex h a u st s y st e m s u pp or t cl a m p

    (Fig. 24). Torque nut s to 23 Nm (17 ft. lbs.).

    (15) Lower the vehicle on hoist.

    (16) Instal l the clutch master cylinder through the

    bulkhead.

    (17) Working from th e inside of the vehicle, Inst all

    the (2) clutch master cylinder retaining nuts.

    (18) C on n ect t h e n eu t ra l s a fet y s w it ch a t t h e

    clutch pedal.

    Fig. 19 Turbocharger / Exhaust Manifold Assembly

    Fig. 20 R.H.D. Turbo Position & Orientation

    Fig. 21 2.5L Turbo Diesel Heatshields

    11 - 8 EXHAUST SYSTEM AND TURBOCHARGER XJ

    REMOVAL AND INSTALLATION (Continued)

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    (1 9 ) I n s t a l l t h e Kn e e B l o c k e r . R e f e r t o Gr o u p 8 E ,

    Instrument Panel Systems for procedure.

    (20) Instal l the clutch master cylinder heatshield.

    (21) I n st a l l t h e i nt a k e m a n if ol d el bow a n d t h e

    E G R v a l v e a s a n a s s e m bl y. Tor q u e t h e i n t a k e e l bow

    bolts to 27 Nm (20 ft. lbs.).

    (2 2 ) I n s t a l l t h e (2 ) bo l t s h o l d i n g t h e E GR t u be t o

    the EG R valve. Torque to bolts 27 Nm (20 ft . lbs.).

    (23) Torque the E G R t ube on the exha ust man ifold

    to 28 Nm (21 ft. lbs.).

    (24) Insta l l t he innercooler inlet an d outlet hoseson the engine.

    (25) I n s t a l l t h e E G R v a c uu m s u pp ly h os e o n t h e

    E GR v a l v e .

    (2 6 ) I n s t a l l t h e a i r f i l t e r c o v e r a n d o u t l e t h o s e o n

    the turbocha rger.

    (2 7 ) C o n n e c t t h e br e a t h e r h o s e o n t h e a i r c l e a n e r

    outlet hose.

    (28) Instal l the heater core coolant supply and the

    brake vacuum supply l ines in there original position.

    (29) Connect the negative battery cable.

    (30) F i ll t h e cool in g s y st e m. R ef er t o G r o up 7,

    Cooling System for the procedure.

    (31) Start the engine and check for leaks.

    Fig. 22 Exhaust Downpipe Heatshield

    Fig. 23 Turbocharger Oil Return Hose

    Fig. 24 Exhaust System Inlet Pipe Connection

    XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 9

    REMOVAL AND INSTALLATION (Continued)

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    10/10

    INTAKE MANIFOLD

    REMOVAL(1) R em ov e e xh a u s t m a n i fol d a n d t u r boch a r g er

    assembly.

    (2) Remove water manifold.

    (3) Remove intake manifold.

    CLEANINGC l e a n t h e i n t a k e m a n i f o l d a n d c y l i n d e r h e a d m a t -

    ing surfaces. DO NOT allow foreign material toenter either the intake manifold or the ports inthe cylinder head.

    INSTALLATION(1 ) I n s t a l l t h e n e w i n t a k e m a n i f o l d g a s k e t .

    (2 ) P o s i t i o n t h e i n t a k e m a n i f o l d i n p l a c e a n d f i n -

    g e r t i g h t e n t h e m o u n t i n g n u t s .

    (3) Ti g h t en t h e f a s t e n er s i n s eq u e n ce a n d t o t h e

    specified torque 30 Nm.(4) Position the water manifold in place and finger

    t i g h t e n t h e m o u n t i n g n u t s .

    (5) Tighten t he fa steners to the specified torque 12

    Nm.

    (6) I n st a l l ex ha u s t m a n if ol d a n d t u rb och a r ger

    assembly.

    (7 ) I n s t a l l c h a r g e a i r c o o l e r h o s e t o i n t a k e m a n i -

    fold.

    (8) Connect the battery negative cable.

    (9) Start engine and check for leaks.

    SPECIFICATIONS

    TORQUE SPECIFICATIONS

    Description Torque

    EGR

    At t a ch i n g Nu t s . . . . . . . . . . . . . . . . . . . . . . . 28 N mEGR

    Tu be Nu t . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N m

    EGR

    Tu be Fl a n g e B o lt s . . . . . . . . . . . . . . . . . . . . 26 Nm

    Exhaust Manifold

    Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm

    Exhaust Manifold

    H e a t Sh i e ld Nu t s . . . . . . . . . . . . . . . . . . . . . 11 Nm

    Exhaust Pipe

    Su p por t C l a m p B ol t s . . . . . . . . . . . . . . . . . 22.5 Nm

    Exhaust Pipe

    Su p por t C l a m p Sc r ew . . . . . . . . . . . . . . . . 22.5 NmIntake Manifold

    Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm

    Muffler-to-Exhaust Pipe

    C l a m p Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . 43 Nm

    Tail Pipe Clamp

    H a n g er bo lt . . . . . . . . . . . . . . . . . . . . . . . . 22.5 Nm

    Turbocharger-to-Exhaust manifold

    Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm

    Turbocharger

    Oil Feed Line . . . . . . . . . . . . . . . . . . . . . . . 27.4 Nm

    Turbocharger Down Pipe-to-Exhaust Pipe

    B olts/Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 Nm

    Turbocharger Down Pipe-to-Turbocharger

    B o l t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N m

    11 - 10 EXHAUST SYSTEM AND TURBOCHARGER XJ

    REMOVAL AND INSTALLATION (Continued)