Exhaust Manifold, Removing and Installing

Exhaust Manifold, Removing And Installing

Removing







- Remove section of engine cover from cylinder head cover.







- Remove cover in front of intake manifold.







- Remove sound insulation (arrows).
- Unbolt heat shield for right drive axle.
- Remove front exhaust pipe.

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







- Remove air hose -1- between upper air line and lower air line.
- Unbolt bracket -2- for upper air line.

NOTE: Do not disconnect oil return line -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 line (bolt -4-).

Disconnect air intake hose from connection on turbocharger as follows:







- Disconnect vacuum line -1- from air recirculation valve.
- Disconnect hose from pressure control valve -2- for crankcase breather.
- Disconnect connector -3- from Wastegate bypass regulator valve -N75-.
- Disconnect hose -4- from Wastegate bypass regulator valve -N75-.
- Remove hose -5- from bulkhead (hose runs between solenoid valve and turbocharger).
- Remove wastegate bypass regulator valve from intake air hose and place valve to one side on engine.
- Remove hose from bulkhead (hose runs between EVAP canister and turbocharger).
- Pull locking clip out of turbocharger connection and take off air intake hose.







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







- Unbolt turbocharger (arrows) from exhaust manifold.
- Remove gasket.

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 performed in the reverse order.

Tightening torques

Components Nm
Clamps for air lines 10 Nm
Heat shield to manifold 10 Nm
Turbocharger bracket to turbocharger 30 Nm
Turbocharger bracket to cylinder block 25 Nm
Turbocharger to exhaust manifold 30 Nm
Exhaust manifold to cylinder head 25 Nm
Front exhaust pipe to turbocharger 40 Nm
Drive axle heat shield to cylinder block 35 Nm
Nuts for clamp 40 Nm
Nuts on connecting flange of catalytic
convert 25 Nm
Heated Oxygen Sensor (HO2S) in front pipe 55 Nm