Exhaust Manifold - INGENIUM I4 2.0L Diesel - High Power (G1914797): Installation

WARNING: This page is about a different variant/trim than selected.

Install a new exhaust manifold gasket.
Renew Part: Exhaust manifold gasket Quantity: 1 .
CAUTION: This step only applies if the original cylinder head is installed.

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- Install the special tool as illustrated.
  Special Tool(s): 303-1444-01
- Install the exhaust manifold.
CAUTION: This step only applies if a new cylinder head is installed.

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- Install the special tool as illustrated.
  Special Tool(s): 303-1444-02
- Install the exhaust manifold.
CAUTION: Bolts must be Tightened in the sequence illustrated.

Fig 1: Exhaust Manifold Bolts Tightening Sequence
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Install the exhaust manifold. Install new bolts and spacers.

Install the Special Tool(s): JLR-303-1652

Renew Part: Exhaust manifold bolts and spacers Quantity: 1 .

Torque : 15 Nm
Remove the special tools.
Special Tool(s): 303-1444-01 , 303-1444-02
CAUTION: Bolts must be Tightened in the sequence illustrated.

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Install the remaining bolts and spacers.

Remove the Special Tool(s): JLR-303-1652

Renew Part: Exhaust manifold bolts and spacers Quantity: 1 .

Torque

Stage 1: 15 Nm

Stage 2: 28 Nm
Secure the Exhaust Gas Recirculation (EGR) cross over pipe to the exhaust manifold. Install a new gasket.
Renew Part: Exhaust gas recirculation pipe gasket Quantity: 1 .

Torque : 12 Nm
Install the turbocharger support bracket.
Torque

M8: 25 Nm

M6: 10 Nm
Install the turbocharger oil return pipe. Install new seals.
Renew Part: Turbocharger oil return pipe seals Quantity: 1 .

Torque : 11 Nm
Install the exhaust manifold heat shields.
Torque : 9 Nm
Install the turbocharger air outlet pipe. Install new seals.
Renew Part: Turbocharger outlet pipe seals Quantity: 1 .

Torque : 9 Nm
Install the turbocharger oil feed pipe. Install a new banjo bolt and seals.
Renew Part: Turbocharger oil feed pipe banjo bolt washers Quantity: 1 .

Torque : 18 Nm
Connect the turbocharger electrical connector.
Install the low pressure turbocharger.
Refer to: LOW PRESSURE TURBOCHARGER - INGENIUM I4 2.0L DIESEL - HIGH POWER
Connect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT