Exhaust Manifold: Service and Repair

WM 261019 Removing and installing exhaust manifold

Preliminary work

1. Remove primary catalytic converter.
-> 267619 Removing and installing primary catalytic converter 267619 Removing and installing primary catalytic converter

Removing exhaust manifold

Removing exhaust manifold, cylinders 1 - 4

1. Remove exhaust manifold heat shield.





Exhaust manifold heat shield (cylinders 1 - 4 shown here)

1.1. Remove fastening screws -A and B-.
1.2. Remove outer heat shield -C-.
2. Remove fastening nuts -1 to 12-.





Exhaust manifold fastening nuts





3. Remove exhaust manifold -5- , heat shield and seal -2-.





Exhaust manifold seal and mount on naturally aspirated engine, cylinders 1 to 4





Removing exhaust manifold, cylinders 5 - 8

1. Remove heat shield -1- above universal joint.





Heat shield (shown here with primary catalytic converter installed)

1.1. Remove fastening screws -2-.
1.2. Remove heat shield -1-.
2. Remove universal joint -1-.

Information

- Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering wheel in centre position with steering wheel holder). If this is not done, the airbag contact unit will have to be put in the centre position after installation of the steering gear -> 945019 Removing and installing steering column switch Service and Repair





Removing universal joint

2.1. On vehicles with Servotronic: Pull off connector -3-.
2.2. Detach holder at cable for Servotronic connector and set cable to one side.
2.3. Unscrew clamping screw -2-.
2.4. Slide universal joint -1- and lower part of steering column upwards.
3. Remove exhaust manifold heat shield.





Exhaust manifold heat shield (cylinders 1 - 4 shown here)

3.1. Remove fastening screws -A and B-.
3.2. Remove outer heat shield -C-.
4. Remove fastening nuts -1 to 12-.





Exhaust manifold fastening nuts





5. Remove exhaust manifold -1- , heat shield and seal -2-.





Exhaust manifold seal and mount on naturally aspirated engine, cylinders 5 to 8





Installing exhaust manifold

Installing exhaust manifold, cylinders 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.

- Clean sealing faces. The sealing faces must be free from foreign objects.

Information

The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other affected assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

1. Insert exhaust manifold -1- , heat shield and seal -2-.





Exhaust manifold seal and mount on naturally aspirated engine, cylinders 1 to 4





2. Fit fastening nuts -1 to 12- in the prescribed sequence.





Tightening sequence for exhaust manifold fastening nuts





3. Fit exhaust manifold heat shield.





Exhaust manifold heat shield (cylinders 1 - 4 shown here)

3.1. Position outer heat shield -C-.
3.2. Fit fastening screws -A and B-.

Installing exhaust manifold, cylinders 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.

- Clean sealing faces. The sealing faces must be free from foreign objects.

Information

The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other affected assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

1. Insert exhaust manifold -1- , heat shield and seal -2-.





Exhaust manifold seal and mount on naturally aspirated engine, cylinders 5 to 8





2. Fit fastening nuts -1 to 12- in the prescribed sequence.





Tightening sequence for exhaust manifold fastening nuts





3. Fit exhaust manifold heat shield.





Exhaust manifold heat shield (cylinders 1 - 4 shown here)

3.1. Position outer heat shield -C-.
3.2. Fit fastening screws -A and B-.
4. Fit universal joint -1-.

Information

- Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering wheel in centre position with steering wheel holder). If this is not done, the airbag contact unit will have to be put in the centre position after installation of the steering gear -> 945019 Removing and installing steering column switch Service and Repair





Fitting universal joint

4.1. Pull universal joint -1- and lower part of steering column downwards -direction arrow-.
4.2. Fit clamping screw -2-.
4.3. On vehicles with Servotronic: Insert connector -3-.
4.4. Fit holder at cable of Servotronic connector.
5. Fit heat shield -1- between steering gear universal joint and primary catalytic converter.





Heat shield

5.1. Insert heat shield -1-.
5.2. Fit fastening screws -2-.

Subsequent work

1. Install primary catalytic converter.
-> 267619 Removing and installing primary catalytic converter 267619 Removing and installing primary catalytic converter