Exhaust Manifold: Service and Repair

Exhaust manifold, removing and installing
Removing

Notes:
^ Always replace gaskets and self-locking nuts.
^ To avoid damage, do not bend decoupling element of front exhaust pipe by more than 10°.





^ Remove engine cover-arrows-.





^ Remove air cleaner cover -arrow-.





^ Remove bolts -arrows-.
^ Disengage EVAP canister purge regulator valve -N80 -1- from air duct -2 -.
^ Remove both screws -arrows- for air duct -2-.





^ Disconnect wires / unplug connectors from:
1- ACE valve
2- Mass Air Flow sensor
3- Wastegate bypass regulator valve -N75
^ Disconnect hoses -4 to 7-.





^ Disconnect hose to secondary air motor -8-.
^ Move wires clear.
^ Unbolt air cleaner housing -9-.
^ Remove air cleaner.

Note: Vacuum line to secondary air combination valve is clipped to underside of air Stake hose.





^ Remove noise insulation -arrows-.





^ Remove bolts -1- and -2- a few turns.





^ Pull front hose off crankcase breather line -2-.
^ Pull front hose off line to secondary air combination valve -1-.
^ Remove heat shield -3-.





^ Remove bolts -1- and -2- of oil supply line.
^ Remove bolts -3- for turbocharger.
^ Remove gasket between turbocharger and exhaust manifold.
^ Plug opening in turbocharger with clean cloth.





^ Remove all nuts -arrows- on exhaust manifold.
^ Remove washers and exhaust manifold.

Installing
Install in reverse order:
^ Keep to following sequence:
^ Make sure that sealing surface is clean
^ Exhaust manifold to cylinder head
^ Turbocharger to exhaust manifold
^ Turbocharger bracket to cylinder block
^ Turbocharger bracket to turbocharger





Tightening torques
1) Replace bolts
2) Coat thread and contact surface of bolt head with hot bolt paste "G 052 112 A3"
3) Bolt strength: 10.9