Exhaust Manifold: Service and Repair

Exhaust Manifold/Gasket, Replacing

Special Tools: 999 5543

NOTE: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Preparation

Remove
- the right front wheel
- the splash guard under the engine
- the right drive shaft.

Remove







- the heat deflector plate above the coolant pipes and hoses for the oil cooler
- the support bracket between the cylinder block and the manifold and three-way catalytic converter (TWC)
- the nuts where the front exhaust pipe and three-way catalytic converter (TWC) join.

Remove the brake pipe from the holders at the front SIPS member.

Remove the screws holding the SIPS member to the bodywork.

Unhook the rubber mountings for the rear exhaust system from the holders.

Pull the exhaust system back so that it releases from the flange at the manifold and three-way catalytic converter (TWC). Put it to one side.

Remove







- the engine stabilizer brace between the suspension turrets
- the air preheating hose between the air cleaner (ACL) and the heat deflector plate.

Disconnect the connector for the front heated oxygen sensor (HO2S).

Remove the heated oxygen sensor (HO2S) wiring from the rear engine mounting.

Remove the front heated oxygen sensor (HO2S).

Seal the opening for the heated oxygen sensor (HO2S).

Remove the upper heat deflector plate over the manifold.

Removing the exhaust manifold and three-way catalytic converter (TWC)

Remove







- the nuts securing the manifold and the three-way catalytic converter (TWC) to the cylinder head
- lift the manifold and three-way catalytic converter (TWC) off the studs at the cylinder head
- the gaskets.

Installing the exhaust manifold and three-way catalytic converter (TWC)

NOTE: Ensure that there is no exhaust leakage.

- Clean the gasket faces. Check that the studs are tightened.
- Install new gaskets.
- Lubricate the studs. Use paste 116 1408.

WARNING: Avoid skin contact with the paste.

- Seal the thread for the upper heated oxygen sensor (HO2S).







- Lift and install the manifold and three-way catalytic converter (TWC). Check that the gaskets are correctly positioned.

Install







- the nuts securing the manifold to the cylinder head. Use new nuts. Tighten to 25 Nm
- the heat deflector plate above the manifold.

Install the upper heated oxygen sensor (HO2S). Lubricate the threads. Use paste 116 1408.

WARNING: Avoid skin contact with the paste.

Tighten the heated oxygen sensor (HO2S). Tighten to 45 Nm. Use tool 999 5543.

Connect the connectors for the heated oxygen sensor (HO2S) to the wiring at the rear edge of the transmission.

Secure the heated oxygen sensor (HO2S) wiring at the rear engine mounting (2 mounting points).

Finishing

Install







- the air preheating hose between the heat deflector plate and the air cleaner (ACL)
- the engine stabilizer brace between the suspension turrets.







- the front exhaust pipe on the manifold and three-way catalytic converter (TWC). Use a new gasket and new nuts. Lubricate the threads with paste 116 1408. Tighten the nuts. Tighten to 25 Nm.

WARNING: Avoid skin contact with the paste.

- the rubber mounting for the rear exhaust system
- the front SIPS member. Tighten to 25 Nm
- the brake pipe on the plastic holders at the front SIPS member
- the support bracket between the cylinder block and the manifold and three-way catalytic converter (TWC). Tighten the screws
- the heat deflector plate above the coolant pipes and hoses
- the right drive shaft.
- the splash guard under the engine
- the right front wheel.

Check
Test run the engine. Check for any leakage from the exhaust system and manifold.