Exhaust Manifold Gasket: Service and Repair

Exhaust manifold / gasket, replacing

Special tools:
999 5972 FIXTURE 999 5972 Fixture

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 in the illustrations is always correct.

Separating the exhaust system





Remove:
- the lower engine cover
- the nuts where the manifold and front exhaust system separate
- the screws for the front SIPS member.
Disconnect the brake pipe from the clips on the SIPS member.
Release the exhaust system from the manifold.
Leave the exhaust system resting on the rear SIPS members.

Removing heated oxygen sensors (HO2S)




Disconnect the connectors for the heated oxygen sensors (HO2S).

Remove:
- the tie strap for the servo hose on the torque rod
- the torque rod
- the preheating hose.
Disconnect the wiring for the heated oxygen sensors (HO2S) from the clips and clamp.
Remove the heated oxygen sensors (HO2S).

Removing the manifold




Remove the heat deflector plate over the manifold.

Note! Clean and spray the exposed threads using rustproofing agent before beginning removal.

Remove the manifold mounting nuts on the engine.
Pull off and lift up the manifold.

Cleaning
Remove the gaskets.
Clean the gasket faces thoroughly. Use a razor blade or a gasket scraper.
Check that all the studs are tightened in the cylinder head. Tighten to 20 Nm.

Installing the manifold

Note! for tightening torques, see: Tightening torque Tightening Torque.

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.

Installing the manifold




Install new gaskets.
Lubricate the threads on the studs and heated oxygen sensors (HO2S) before installation. Use paste 116 1408.

Install
- the manifold. Use new nuts. Tighten to 25 Nm
- the heat deflector plate
- the heated oxygen sensors (HO2S). Tighten to 45 Nm.
Connect the heated oxygen sensor (HO2S) connectors.

Installing the exhaust system




Install new gaskets on the manifold flanges.
Connect the front exhaust pipe to the manifolds.
Lubricate the threads. Use new nuts. Tighten to 25 Nm.
Press the brake pipe into the clip on the front SIPS member.
Press up and install the front SIPS member. Tighten to 25 Nm.
Install the lower engine cover.

Finishing

Install:
- the wiring for the heated oxygen sensors (HO2S) using the clip and the clamp
- the preheating hose
- torque rod.
Install the servo hose on the torque rod using a tie strap.
Test drive the engine.
Check for leakage.