Exhaust manifold, removing and installing
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. Refer to Front exhaust pipe, removing and installing .
NOTE:
The de-coupling element on the front exhaust pipe may only be bent slightly - not more than 10°.
- 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 |
| Heat shield to manifold | 10 |
| Turbocharger bracket to turbocharger | 30 |
| Turbocharger bracket to cylinder block | 25 |
| Turbocharger to exhaust manifold | 30 |
| Exhaust manifold to cylinder head | 25 |
| Front exhaust pipe to turbocharger | 40 |
| Drive shaft heat shield to cylinder block | 35 |
| Nuts for clamp | 40 |
| Nuts on connecting flange of Catalytic converter |
25 |