Exhaust Manifold: Service and Repair
Removing And Installing Exhaust Manifold
Technical values
Removing exhaust manifold
DANGER:
Parts of the exhaust system become extremely hot.
- Danger of burns
- Permanent scarring of the skin
- Do not begin work until the exhaust system has cooled down completely.
- If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat resistant protective gear.
INFORMATION: The numbers shown in boxes in the component overviews indicate the tightening sequence. Always follow the specified sequence.
Component overview M 96/05 (3.6 l)
Component overview M 97/01 (3.8 l)
1. Loosen threaded flange joint to catalytic converter -1-. Replace lock nuts.
2. Unscrew hexagon-head bolts (M8 x 26) -1- on exhaust manifold and remove manifold. Replace bolts.
3. Remove exhaust manifold seal and carefully clean sealing surfaces on the cylinder head and manifold.
4. Check exhaust manifold for damage and cracks.
Installing exhaust manifold
1. Position new metal seal on cylinder head. The beading must point to the sealing surface of the cylinder head.
INFORMATION: Observe installation position of three-hole flange seal. The beading is facing the exhaust manifold and the edges must not project over the contour of the flange.
2. Insert exhaust manifold on catalytic converter flange with a new seal and secure evenly to the cylinder head with two new screws. Then screw in the remaining (new) screws. Observe installation position of seal on catalytic converter flange.
3. Fit three new lock nuts on catalytic converter flange and screw on slightly.
INFORMATION: The numbers shown in boxes in the component overviews indicate the tightening sequence. Always follow the specified sequence.
4. Tighten screws for exhaust manifold -1- in accordance with the tightening sequence (see relevant component overview). - Tightening torque: 23 Nm (17 ftlb.)
5. Tighten new lock nuts -1- on catalytic converter flange. - Tightening torque: 23 Nm (17 ftlb.)