Removing Exhaust Manifold For Cylinder Bank 1 - 4

Information 

The pictures shown in this document may differ from the original.

Information 

On turbo engines, there is no need to remove the primary catalytic converter and turbocharger when removing the exhaust manifold.

1. Remove heat shields on the exhaust manifold for cylinder bank 1 - 4 and on the generator. -arrows- 

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   Heat shields for cylinders 1 - 4

2. Remove heat shield on exhaust manifold for cylinders 5 - 8.

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   Heat shield for cylinders 5 - 8

   1. 2.1  Loosen fastening screws -1-  on the heat shield.
   2. 2.2  Unclip heat shield -2-  from the holders -3-  .
3. Unclip the oxygen sensor cable from all holders. Remove oxygen sensor when replacing the exhaust manifold.

   Cylinders 1 to 4 > Oxygen sensor on naturally aspirated engine, cylinders 1 to 4  .

   Fig 1: Oxygen Sensor Components Location - Naturally Aspirated Engine, Cylinders 1 To 4

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   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

4. Spray fastening nuts on the exhaust manifold with anti-rust agent if necessary.
5. Loosen the fastening nuts in reverse order  to the sequence shown below > Tightening sequence for exhaust manifold on naturally aspirated engine, cylinders 1 to 4  . Remove exhaust manifold. Replace fastening nuts.
   Fig 2: Exhaust Manifold Screws Loosening Sequence - Naturally Aspirated Engine, Cylinders 1 To 4

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

6. Only for vehicles with turbocharger: 

   Loosen fastening screws -4-  for the turbocharger.

   The turbocharger and the primary catalytic converters must not be removed. 

7. Only for vehicles with turbocharger: 

   Loosen the fastening nuts on the exhaust manifold in reverse order to the sequence shown and remove them > Tightening sequence for exhaust manifold on turbo engine, cylinders 1 to 4  . Remove exhaust manifold. Replace nuts.

   Fig 3: Exhaust Manifold Screws Loosening Sequence - Turbo Engine, Cylinders 1 To 4

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

8. Remove the seal and replace it. Clean sealing faces. Cylinders 1 to 4 > Exhaust manifold on naturally aspirated engine, cylinders 1 to 4  .
   Fig 4: Exhaust Manifold Components Location - Naturally Aspirated Engine, Cylinders 1 To 4

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   Exhaust manifold on naturally aspirated engine, cylinders 1 to 4

   1	Exhaust manifold
   2	Exhaust manifold seal
   3	Hexagon nut, M8
   4	Oxygen sensor
   A	Marking on seal visible from outside

9. Only for vehicles with turbocharger: 

   Remove seal and replace it. Clean sealing faces. Cylinders 1 to 4 > Exhaust manifold on turbo engine, cylinders 1 to 4  .

   Fig 5: Exhaust Manifold Components Location - Turbo Engine, Cylinders 1 To 4

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   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	Hexagon nut M8
   A	Marking on seal visible from outside