Removal and Installation

NOTE: Exhaust manifolds are single.flow pipes. Bellows are attached for compensation of heat expansion.

Engine 116. 963:

Engine 117.963:

To prevent distortions, the exhaust manifold on engine 116.963 and 117.963 have been reinforced between exhaust ducts (arrows). The shielding plates have been simultaneously modified. When renewing modified exhaust manifolds, also renew shielding plates.

Replacement Parts:

Supply responsibility Works 50 (PEW Sindelfingen)

Removal:
1 Pull off ignition cable.
2 Unscrew shielding plates on exhaust manifold

Exhaust Manifold, Left (Steps 3 - 5)





3 Remove clamp for transverse tube.
4 Unscrew exhaust gas recirculation line on valve.
5 Unscrew exhaust nuts and screws and remove Exhaust manifold, left.

Exhaust Manifold, Right (Steps 6 - 9):





6 Remove exhaust system. Service and Repair
7 Remove clamp for transverse tube.
8 Remove air cleaner.
9 Unscrew exhaust nuts and screws and remove exhaust manifold.


Installation:
10 For installation proceed vice versa. Renew all gaskets and exhaust nuts. Before tightening, put on screws for holder. Flange transverse tube before exhaust manifold is tightened.





A Engine 117.96
B Engine 116.96

11 Mount flange gaskets with sheet metal in direction of cylinder head.
During assembly make sure that the exhaust manifold gaskets are not mixed up.
12 Mount exhaust system.
13 Mount air cleaner. Pay attention to correct seat of sealing ring between air flow sensor and air cleaner.
14 Run engine and check exhaust system for leaks.