Exhaust Manifold: Service and Repair

Removing





^ Remove section of engine cover from cylinder head cover.





^ Remove cover in front of intake manifold.





^ Remove noise insulation - arrows -.
^ Unbolt heat shield for right drive axle.
^ Remove front exhaust pipe.

Notes: The de - coupling element on the front exhaust pipe may only be bent slightly (not more than 10°).





^ Remove air hose - 1 - between upper air pipe and lower air pipe.
^ Unbolt bracket - 2 - for upper air pipe. Do not disconnect oil return pipe - 3 - for turbocharger.





^ Loosen bolted connection - 3 - for turbocharger bracket by a few turns.
^ Remove turbocharger bracket from cylinder block (bolts - 1 - and - 2 -).
^ Unbolt bracket for coolant return pipe (bolt - 4 -).

Detach air intake hose from connection on turbocharger as follows:





^ Disconnect vacuum pipe - 1 - from air recirculation valve.
^ Disconnect hose from pressure control valve - 2 - for crankcase breather.
^ Unplug connector- 3 - from charge pressure control valve - N75.
^ Disconnect hose - 4 - from charge pressure control valve - N75.
^ Detach hose - 5 - from bulkhead (hose runs between solenoid valve and turbocharger).
^ Remove charge pressure control valve from intake air hose and place valve to one side on the engine.
^ Detach hose from bulkhead (hose runs between activated charcoal filter and turbocharger).
^ Pull locking clip out of turbocharger connection and take off air intake hose.





^ Disconnect hose - 2 - (leading to turbocharger) and detach hose - 1 - from upper air pipe.
^ Remove bolts on heat shield on back of cylinder head.
^ Release clamps - 3 - and - 4 - on air pipe.
^ Remove upper air pipe and heat shield.





^ Unbolt turbocharger - arrows - from exhaust manifold.
^ Remove gasket.
^ The turbocharger will drop down slightly.





^ Remove all nuts - arrows - on exhaust manifold (nuts can be reached from above). Remove washers and exhaust manifold.

Installing
Installation is carried out in the reverse order.