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

WARNING: This page is about a different variant/trim than selected.

Notes

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 work:

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.

Fig 1: Identifying Intake Pipe, Charge-Air Duct And Gaiter With Clamp

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

Fig 2: Releasing Spring Strap Using Special Tool 17 2 051

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Release screws and detach lines (1).

Installation note:

Replace gaskets.

Tightening torque N14 11 65 8AZ .

Fig 3: Locating Lines Screws

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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.

Fig 4: Releasing Spring Strap Using Special Tool 17 2 051

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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 .

Fig 5: Identifying Lines Screws

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Installation note: When fitting engine oil pipe and banjo bolt, install thermal protection (1)

Wrap thermal protection around engine oil pipe. Check banjo bolt (2) and engine oil pipe for blockage. Replace blocked banjo bolt and engine oil pipe.

Fig 6: Identifying Heat Shield And Banjo Bolt

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Installation note: Make sure that thermal protection clamp (1) engages correctly.

Fig 7: Identifying Heat Shield Clamp

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Release screw (1).

Tightening torque 11 65 3AZ .

Release screw (2) and remove holder (3).

Tightening torque 11 65 6AZ .

Fig 8: Identifying Holder Screw

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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 .

Fig 9: Locating Exhaust Manifold Screws

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Release nuts and remove exhaust turbocharger (1) from exhaust manifold (2).

Installation note:

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

Fig 10: Locating Exhaust Manifold Nuts

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NOTE: Assemble engine.

TOP UP COOLANT.

Check engine oil level.

Clear DME fault memory.