Installing Exhaust Manifold For Cylinder Bank 5 - 8

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.

> TECHNICAL VALUES

> 2X00IN TECHNICAL VALUES

or

> WM, 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS FOR ENGINE

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.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Exhaust manifold on naturally aspirated engine, cylinders 5 to 8

   1	Exhaust manifold
   2	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 1: Exhaust Manifold Screws Tightening Sequence - Naturally Aspirated Engines, Cylinders 1 To 4 (Identical To Cylinders 5 To 8)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tightening sequence for exhaust manifold on naturally aspirated engines, cylinders 1 to 4 (identical to cylinders 5 to 8)

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 2: Exhaust Manifold Components Location - Turbo Engine, Cylinders 5 To 8

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Exhaust manifold on turbo engine, cylinders 5 to 8

   1	Exhaust manifold
   2	M8 hexagon nut; (check nuts by clicking once); observe correct tightening sequence
   3	Screw, M8 x 75
   4	Turbocharger seal
   5	Exhaust manifold seal
   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 3: Exhaust Manifold Screws Loosening Sequence - Turbo Engines, Cylinders 1 To 4 (Identical To Cylinders 5 To 8)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tightening sequence for exhaust manifold on turbo engines, cylinders 1 to 4 (identical to cylinders 5 to 8)

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

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Oxygen sensor on naturally aspirated engine, cylinders 5 to 8

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