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

Special tools required:

17 2 051

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 tasks:

Drain COOLANT .
Remove COOLANT EXPANSION TANK .
Remove the CATALYTIC CONVERTER .

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 Charge Air Duct Clamp, Gaiter With Clamps And Intake Pipe

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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 engine: 11 65 8AZ .

Tightening torque, N18 engine: 11 65 9AZ .

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 With Special Tool (17 2 051)

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Release screw (1) and detach line (2).

Installation note:

Replace gaskets.

Tightening torque, N14 engine: 11 65 4AZ . Tightening torque, N18 engine:11 65 4AZ .

Release screw (3) and detach line (4).

Installation note:

Replace sealing ring.

Tightening torque, N14 engine: 11 65 5AZ . Tightening torque, N18 engine: 11 65 5AZ .

Fig 5: Identifying Line With Screw

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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 Thermal Protection And Banjo Bolt

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Installation note:

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

Fig 7: Identifying Thermal Protection Clamp

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Release screw (1).

Tightening torque, N14 engine: 11 65 3AZ . Tightening torque, N18 engine: 11 65 3AZ .

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

Tightening torque, N14 engine: 11 65 6AZ . Tightening torque, N18 engine: 11 65 6AZ .

Fig 8: Identifying Holder With Screws

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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 Nuts

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

Observe important information during removal or replacement of the exhaust turbocharger. See REMOVING AND INSTALLING/REPLACING EXHAUST TURBOCHARGER (N14) or REMOVING AND INSTALLING/REPLACING EXHAUST TURBOCHARGER (N18) .

Installation note:

Replace gasket and nuts.
Clean sealing surfaces.
Apply a thin coat of copper paste to thread.
Tightening torque, N14 engine: 11 65 1AZ . Tightening torque, N18 engine: 11 65 1AZ .

Fig 10: Locating Exhaust Turbocharger Nuts

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NOTE: Assemble engine.

TOP UP COOLANT .

Check engine oil level.

Clear DME fault memory.