Exhaust Manifold: Service and Repair
Exhaust manifold / gasket, replacing
Special tools:
999 5972 FIXTURE 999 5972 Fixture
Removing manifold / gasket
Note! 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.
Note! To simplify the following text, the terms turbo 1 and turbo 2 are used. Turbo 1 is for cylinders 1,2,3. Turbo 2 is for cylinders 4, 5, 6.
Preparation
Remove
- the screw for the engine stabilizer brace mounting on the engine
- the screws for the engine stabilizer brace mountings between the suspension turrets
- the plastic charge air pipe. Place to one side
- the plastic intake pipe. Put it to one side.
(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)
- the charge air pipe and intake manifold from turbo 1. Seal the openings
- the heat deflector plate from turbo 1.
(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)
- the screw for the upper mounting for the automatic transmission dipstick pipe. Slacken off the screw on the lower mounting
- the intake manifold and the charge air pipe to turbo 2. Seal the openings
- the heat deflector plate from turbo 2
- the expansion tank cap.
Raise the car.
Remove the left front wheel.
Remove the splash guard under the engine.
Connect a hose to the engine drain cock. Drain the coolant into a clean container.
Close the cock.
Remove
- the rear SIPS member
- the nuts for the rear flange seals on the catalytic converters
- the nuts for the front flange seals on the catalytic converters.
Expose the heated oxygen sensor (HO2S) wiring. Disconnect the connectors.
Disconnect the brake pipe from the holders on the front SIPS member.
Position a mobile jack with universal plates 999 5972 FIXTURE 999 5972 Fixture under the catalytic converters.
Remove the screws for the front SIPS member.
Pull back and lower the catalytic converters with their heat deflector plates.
Note! The routing of the heated oxygen sensor (HO2S) wiring over the brake pipe.
Note! The front exhaust pipe intermediate hose is easy to damage if it is twisted. Handle the exhaust hose with care to avoid leakage later.
Remove
- the right-hand drive shaft. See Drive shaft right, replacing Drive Shaft Right, Replacing
- the pipe screws for the coolant pipes. Place the pipes to one side
- the pipe screws for the oil pressure outlet on the engine
- the clamp between the oil pressure pipe and the intake pipe to the water pump
- the oil return pipe screws. Carefully turn the pipes to one side.
(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)
Lower the car.
- the pipe screws for the oil pressure pipe connection in the central housings
- the oil pressure pipe from turbo 1
- upper coolant pipe with hose to turbo 2.
Removing turbo 1 / manifold
Note! Clean and spray the exposed threads with rustproofing agent before beginning removal.
Remove the manifold mounting nuts on the engine.
Pull off and lift up the turbocharger (TC) / manifold.
Removing turbo 2 / manifold
(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)
Note! Clean and spray the exposed threads with rustproofing agent before beginning removal.
Remove the manifold mounting nuts on the engine.
Pull off and lift up the turbocharger (TC) / manifold.
Note! The oil pressure pipe withdraws from the turbocharger (TC) / manifold at the same time.
Installing manifold / gasket
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Replacing manifold
Transfer the turbocharger (TC) to the new manifold.
Lubricate the stud threads. Use paste, P/N: 116 1408. Avoid skin contact with the paste.
Install new nuts. Tighten to 25 Nm.
Replacing gasket
Remove the old gaskets.
Clean the gasket faces thoroughly. Use a razor blade or a plastic scraper. Clean around all exhaust ports.
Ensure that all the studs are tightened in the cylinder head. Tighten to 20 Nm.
Install new gaskets.
Install turbo 2 / manifold
Lubricate the stud threads. Use paste, P/N: 116 1408.
Lower and press the turbocharger (TC) / manifold into place.
Note! Ensure that the oil pressure pipe locates at the same time.
Install the washers and new nuts. Tighten to 25 Nm.
Install turbo 1 / manifold
Lubricate the stud threads with paste, P/N: 116 1408.
Lower and press the turbocharger (TC) / manifold into place.
Install the washers and new nuts. Tighten to 25 Nm.
Finishing
(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)
Install
- the oil pressure pipe with pipe screws to turbo 2. Use new gasket washers. Do not tighten yet
- the oil pressure pipe with pipe screws to turbo 1. Use new gasket washers. Do not tighten yet
- the clamp between the oil pressure pipe for turbo 2 and the intake pipe for the water pump. Do not tighten yet.
(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)
Raise the car.
- the pipescrew for the oil pressure pipe in the connection in the cylinder block. Use new gasket washers. Tighten to 38 Nm
- the oil return line to turbo 1 with new gasket. Tighten to 12 Nm
- the oil return line to turbo 2 with new gasket. Tighten to 12 Nm
- the lower coolant pipe to turbo 1 and 2. Use new gasket washers. Tighten to 26 Nm
- the right drive shaft. See Drive shaft right, replacing Drive Shaft Right, Replacing.
Install the catalytic converter with heat deflector plate. Use new nuts and gaskets. Lubricate all studs. Use paste P/N: 116 1408.
Connect the pipe to the engine. Use a mobile jack with universal plate 999 5972 FIXTURE 999 5972 Fixture as support.
Note! Ensure that the heated oxygen sensor (HO2S) wiring is above the brake pipe.
Press the brake pipe into place on the front SIPS member.
Connect to the rear exhaust pipe. Install all nuts loosely.
Install the screws for the front SIPS member.
Remove the mobile jack.
Tighten
- the nuts for the front flange seal. Tighten crosswise to 25 Nm
- the front SIPS member. Tighten to 25 Nm
- the nuts for the rear flange seal. Tighten to 25 Nm
- the rear SIPS member. Tighten to 25 Nm.
Connect the heated oxygen sensor (HO2S) wiring.
Secure the wiring at the rear edge of the sub-frame.
Install the splashguard under the engine.
Install the left front wheel. See Installing wheels Service and Repair.
Lower the car.
Install both the upper coolant pipes with new gasket washers. Tighten to 26 Nm.
Tighten the oil pressure pipes in the central housings. Tighten to 18 Nm.
Close the clamp between the oil pressure pipe and the water pump intake pipe.
Install
- the screw for the engine stabilizer brace mounting on the engine. Tighten to 80 Nm
- the screws for the engine stabilizer brace mountings in the suspension turrets. Tighten to 50 Nm
- the automatic transmission dip stick pipe
- the heat deflector plate with new screws. Tighten to 25 Nm
- the intake and charge air pipe hooks. Align against the plastic pipes and tighten.
Press the plastic pipes into place. Tighten the hose clamps
- the mounting screws for the plastic pipes
- the expansion tank cap.
Final check
Check
- the coolant level
- the oil level.
Test drive the engine. Check for leakage.
Top up the coolant if necessary.