Table of contents: Removal ↓ Installation ↓
Removal
1. Apply the handbrake, lift the front of the car with a jack, install safety supports. Remove the lower engine cover.
2. Remove the air filter and air ducts - see chapters 4A or 4B. If necessary, remove the top engine cover.
3. On all engines except AEB and AJL, remove the oxygen sensor from the exhaust manifold as described in chapter 4A.
4. On AEB and AJL engines - loosen the turbine bracket mounting bolts only a few turns. Loosen the oil feed pipe mount to the heat shield.
5. Remove the heat shield from the exhaust manifold if necessary.
6. On all engines except AEB and AJL, unscrew the nuts and disconnect the muffler inlet pipe from the exhaust manifold. Remove the gasket and move the pipe away from the manifold.
7. On AEB and AJL engines, unscrew the three bolts securing the turbine to the exhaust manifold, lower the turbine and remove the gasket. Cover the hole in the turbine with a clean cloth to prevent dirt or extra nut from getting inside.
8. Gradually unscrew and remove the nuts with washers, remove the manifold from the head studs. Remove the gasket.
Installation
9. Thoroughly clean the mating surfaces of the head and manifold.
10. Installation - reverse procedure. Install new gaskets, new self-locking nuts and tighten them to the prescribed torque. On AEB and AJL engines, install the exhaust manifold, then the turbocharger on the manifold and secure the turbocharger to the cylinder block. The tightening torques for the threaded connections are given in chapter 4A.