B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 011-007   Exhaust Manifold, Dry

• Remove the turbocharger. Refer to Procedure 010-033-002.

13 mm

Remove the heat shield.

15 mm

Remove the exhaust manifold and gaskets.

Clean the sealing surfaces.

Inspect the exhaust manifold for cracks, burnout, or damaged threads.

Coat all capscrew threads with an unleaded anti-seize compound.

NOTE: Use only anti-seize compound compatible with oxygen sensors.

15 mm

Install the exhaust manifold and new gaskets.

Follow the tightening sequence shown in the illustration.

CAUTION  The system must be filled slowly to prevent air locks. During filling, air must be vented from the engine coolant passages. The system has a maximum fill rate of 14 liters per minute [3.5 gallons per minute]. Do not exceed this fill rate. Wait 2 to 3 minutes to allow air to be vented. Then add coolant to bring the level to the top.

Install the heat shield and turbocharger. Fill the engine with coolant.

Operate the engine, and check for leaks.