Exhaust Manifold: Service and Repair

Exhaust Manifold, Removing And Installing Removing

Removing







- Remove section of engine cover from cylinder head cover.







- Remove cover in front of intake manifold.







- Remove noise insulation (arrows).
- Remove heat shield for right-hand drive shaft.
- 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 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 line -1- from air recirculation valve.
- Disconnect hose from pressure control valve -2- for crankcase breather.
- Disconnect electrical connector -3- from charge air pressure control valve -N75-.
- Disconnect hose -4- from Wastegate Bypass Regulator 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 line.
- 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.

Tightening torques

Components Nm
Clamps for air line 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 shaft heat shield to cylinder block 35 Nm
Nuts for clamp 40 Nm
Nuts on connecting flange of
catalytic converter 25 Nm