Exhaust Manifold: Service and Repair

Exhaust Manifold, Removing And Installing

Removing

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







- 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 wiring connectors from:
1. EVAP valve
2. Mass Air Flow sensor
3. Wastegate bypass regulator valve -N75-

- Disconnect hoses -4 to 7-.







- Disconnect hose to secondary air injection pump motor -8-.
- Move wiring clear.
- Unbolt air cleaner housing -9-.
- Remove air cleaner.

NOTE: Vacuum line to secondary air combination valve is clipped to underside of air intake hose.







- Remove sound insulation (arrows).







- Loosen 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, paying attention to the following:
- Install components in keeping with 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

Component Nm
Exhaust manifold to cylinder head 25
Turbocharger to exhaust manifold 35 1) 2)
Turbocharger bracket to cylinder block 45
Turbocharger bracket to turbocharger
(M8 collared bolt) 40 3)
Oil supply line to cylinder head 20
Crankcase breather line to cylinder head 10
Hose clamps for air hoses 3.5

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