Specifications

(29) Remove the (10) intake manifold retaining
bolts and remove the intake manifold from the vehi-
cle (Fig. 40).
(30) Remove the intake/exhaust manifold gasket
from the manifolds mounting studs.
CLEANING
All old gaskets should be inspected for any tears or
signs of prior leakage. If any gaskets show such indi-
cations, they should be replaced with new gaskets.
All gasket mating surfaces must be cleaned of old
gasket material to produce a smooth and dirt/oil free
sealing surface for the new gasket.
INSTALLATION
(1) Position the new intake/exhaust manifold gas-
ket on the manifolds mounting studs.
(2) Install the intake manifold and install the (10)
retaining nuts (Fig. 40). Torque the nuts to 32 N·m
(23 ft. lbs.).
(3) Position the new intake air duct gasket.
(4) Install the intake air duct on the engine.
Torque the bolts to 32 N·m (23 ft. lbs.).
NOTE: If only servicing the intake manifold the fol-
lowing two steps are not required.
(5) Position the gasket and install the turbo on the
exhaust manifold. Torque the nuts to 32 N·m (23 ft.
lbs.) (Fig. 41).
(6) Remove the assembly from the vice and posi-
tion on the exhaust manifold mounting studs.
(7) Install the exhaust manifold retaining nuts and
torque to 32 N·m (23 ft. lbs.).
(8) Install the transmission dipstick tube in the
transmission case.
(9) Remove the drain pan.
(10) Install the oil pressure supply line on turbo-
charger. Torque bango bolt fitting to 27 N·m (20 ft.
lbs.). Be certain the copper sealing washers are
installed. One on the top and bottom of the supply
line.
(11) Install the EGR tube nut on the exhaust man-
ifold and temporarily install one of the EGR valve
retaining bolts. Be certain the EGR valve gasket is in
place.
(12) Torque the EGR tube retaining nut to 34 N·m
(25 ft.lbs.). Remove the temporarily installed EGR
valve bolt
WARNING: Heatshield is very sharp. Wear gloves
to prevent injury.
(13) Install the exhaust manifold heatshield.
Torque bolts to 11 N·m (97 in. lbs.).
(14) Install the transmission dipstick tube support
bracket retaining nut on the turbocharger heatshield
(Fig. 42). Torque the nut to 20 N·m (177 in. lbs.).
(15) Install the front (front of engine) heater core
coolant supply hoses on the coolant line assembly
and install the line assembly on the engine. Torque
the (3) retaining bolts to 27 N·m (20 ft. lbs.) (Fig. 43).
(16) Connect the crankcase vapor supply and
return hoses on the oil separator.
(17) Install the oil separator retaining bolts.
Fig. 40 Intake Manifold Retaining Nuts
Fig. 41 Turbocharger Retaining Nuts
9 - 26 ENGINE WJ
REMOVAL AND INSTALLATION (Continued)