Installing Exhaust Manifold

Information 

• Visually inspect exhaust manifold for cracks and distortion. 
• A cracked or distorted exhaust manifold must not be reinstalled. 
• As a matter of principle, replace seals on manifold. 
• Replace the studs in the cylinder head if damaged. Measure the studs with respect to the cylinder head and fit new studs to the same screw-in depth as the old studs. 

1. Clean sealing surfaces. The surfaces must be free from foreign objects.
2. Fit lambda sensor when replacing the exhaust manifold (grease the thread of the lambda sensor with a light coating of grease 000.043.207.07, status 06/07).
3. Use a new seal. The seal must be positioned so that the part number is visible from the outside.

   Slide the exhaust manifold over the studs and fit it using new fastening nuts. Tighten the fastening nuts to the prescribed tightening torque. Observe tightening sequence.

   Fig 1: Identifying Exhaust Manifold On Naturally Aspirated Engine M48/01 Mounting Nuts Tightening Sequence

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 2: Identifying Exhaust Manifold On Naturally Aspirated Engine M48/01 (Cylinders 1 To 4)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Exhaust manifold
   2. Exhaust manifold seal
   3. Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence → Tightening torque: 33 Nm (24 ft lbs.) (check nuts by clicking once) 
   4. Lambda sensor → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.) 
   1. Marking on seal visible from outside
      Fig 3: Identifying Exhaust Manifold On Naturally Aspirated Engine M48/01 (Cylinders 5 To 8)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Exhaust manifold
   2. Seal
   3. Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence → Tightening torque: 33 Nm (24 ft lbs.) (check nuts by clicking once) 
   4. Lambda sensor → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.) 
   1. Marking on seal visible from outside
4. Clip lambda sensor cable into the holders.
   Fig 4: Identifying Lambda Sensor On Naturally Aspirated Engine M48/01 (Cylinders 1 To 4)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Lambda sensor on primary catalytic converter → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.) 
   2. Cable attachment
   3. Holder
   4. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.  )
   5. Cable attachment
   1. View A
   2. View B
   Fig 5: Identifying Lambda Sensor On Naturally Aspirated Engine M48/01 (Cylinders 5 To 8)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Lambda sensor on primary catalytic converter → Tightening torque: 45 Nm (33 ft lbs.)+/-5 Nm (+/-3.5 ft lbs.) 
   2. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   3. Holder
   4. Holder
   5. Holder
   6. Cable attachment
   7. Cable attachment
   1. View A
5. Fit heat protection panels. →
   Fig 6: Locating Heat Protection Panels On V8 Naturally Aspirated Engine

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.