Exhaust Manifold: Service and Repair

18 40 040 Removing and installing/replacing the exhaust manifold (N14, N18)

Special tools required:







WARNING:
Risk of burning.
This repair work may only be carried out on an exhaust system which has cooled down.







IMPORTANT:
Gaiter and charge air hoses with clamp fastenings must be installed dry and free from grease.
Sealing surfaces and connecting branches must be dry and free from grease.
If gaiter and charge air hoses with clamp fastenings are not installed dry and free from grease, this may result in exhaust turbocharger failure.







Necessary preliminary tasks:
- Drain coolant.
- Remove coolant expansion tank.
- Remove the catalytic converter.







Release the clamp and detach the charge air duct (1).
Release clamps (2) and pull off gaiter (3).
Remove intake pipe (4).

Installation note:
Install gaiter (3) and charge-air duct (1) dry and free from grease.
Connecting branch on exhaust turbocharger must be dry and free from grease.







Release the spring strap using special tool 17 2 051 and pull off the coolant hose (1).







Release screws and detach lines (1).

Installation note:
Replace gaskets.
Tightening torque N1411 65 8AZ .
Tightening torque N1811 65 9AZ.







Pull off hose (1).
Unlock connector (2) and remove.
Release screw (3).
Release spring strap with special tool 17 2 051. Pull off line (4) and remove.







Release screw (1) and detach line (2).

Installation note:
Replace gaskets.
Tightening torque: 11 65 4AZ.

Release screw (3) and detach line (4).

Installation note:
Replace sealing ring.
Tightening torque 11 65 5AZ.







Release screw (1).
Tightening torque 11 65 3AZ .
Release screw (2) and remove holder (3).
Tightening torque 11 65 6AZ .







Release nuts and remove exhaust manifold (1).

Installation note:
- Replace gasket and nuts.
- Clean sealing surfaces.
- Apply a thin coat of copper paste to thread.
- Tightening torque 18 40 1AZ .







Release nuts and remove exhaust turbocharger (1) from exhaust manifold (2).
Observe important information during removal or replacement of the exhaust turbocharger.

Installation note:
- Replace gasket and nuts.
- Clean sealing surfaces.
- Apply a thin coat of copper paste to thread.
- Tightening torque 11 65 1AZ .







NOTE:
Assemble engine.
Top up coolant.
Check engine oil level.
Clear DME fault memory.