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7/29/2019 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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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)