Installing Exhaust Manifold For Cylinder Bank 1 - 4

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.

Information 

The tightening specifications for the basic engine are stored centrally.

> Refer to the appropriate Technical values service information

/

> 2X00IN TECHNICAL VALUES

or

> Refer to the appropriate Tightening torques, tightening sequences and assembly overviews service information.

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

1. Clean sealing surfaces. The surfaces must be free from foreign objects.
2. Fit oxygen sensor when replacing the exhaust manifold (grease the thread of the oxygen 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.
   Fig 1: Exhaust Manifold Components Location - Naturally Aspirated Engine, Cylinders 1 To 4

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Exhaust manifold on naturally aspirated engine, cylinders 1 to 4

   1	Exhaust manifold
   2	Exhaust manifold seal
   3	M8 hexagon nut; (check nuts by clicking once); observe correct tightening sequence
   4	Oxygen sensor
   A	Marking on seal visible from outside

4. Slide the exhaust manifold over the studs and fit it using new fastening nuts. The fastening nuts will be tightened to the prescribed tightening torque. Observe tightening sequence.
   Fig 2: Exhaust Manifold Screws Tightening Sequence - Naturally Aspirated Engine, Cylinders 1 To 4

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tightening sequence for exhaust manifold on naturally aspirated engine, cylinders 1 to 4

5. Only for vehicles with turbocharger: 

   Use a new seal (the seal for the turbocharger is also replaced). The exhaust manifold seal must be positioned so that the part number is visible from the outside.

   Fig 3: Exhaust Manifold Components Location - Turbo Engine, Cylinders 1 To 4

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Exhaust manifold on turbo engine, cylinders 1 to 4

   1	Exhaust manifold
   2	Exhaust manifold seal
   3	Turbocharger seal
   4	Screw, M8 x 75
   5	M8 hexagon nut; (check nuts by clicking once); observe correct tightening sequence
   A	Marking on seal visible from outside

6. Only for vehicles with turbocharger: 

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

   Fig 4: Exhaust Manifold Screws Tightening Sequence - Turbo Engine, Cylinders 1 To 4

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tightening sequence for exhaust manifold on turbo engine, cylinders 1 to 4

7. Fit fastening screws for the turbocharger.
8. Clip oxygen sensor cable into the holders. > Oxygen sensor on naturally aspirated engine, cylinders 1 to 4 
   Fig 5: Oxygen Sensor Components Location - Naturally Aspirated Engine, Cylinders 1 To 4

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Oxygen sensor on naturally aspirated engine, cylinders 1 to 4

   1	Oxygen sensor on primary catalytic converter
   2	Cable attachment
   3	Holder
   4	Screw, M6 x 12
   5	Cable attachment
   A	View A
   B	View B

9. Fit heat shields. > Heat shields on V8 naturally aspirated engine 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Heat shields on V8 naturally aspirated engine

10. Fit heat shield for cylinder bank 5 - 8.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heat shield for cylinders 5 - 8

    1. 10.1  Clip heat shield -2-  into the holders -3-  .
    2. 10.2  Fit the fastening screws -1-  for the heat shield.