Exhaust Manifold: Service and Repair

Removing And Installing Exhaust Manifold

Preliminary work

1. Remove primary catalytic converter.

Removing exhaust manifold

Removing exhaust manifold, cylinders 1 - 4







1. Remove exhaust manifold heat shield.
1.1. Remove fastening screws -A and B-.
1.2. Remove outer heat shield -C-.







2. Remove fastening nuts -1 to 12-.







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

Removing exhaust manifold, cylinders 5 - 8







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

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







4. Remove fastening nuts -1 to 12-.







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

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.
- The tightening specifications for the basic engine are stored centrally.







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







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







3. Fit exhaust manifold heat shield.
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.
- The tightening specifications for the basic engine are stored centrally.







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







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







3. Fit exhaust manifold heat shield.
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.

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

Subsequent work

1. Install primary catalytic converter.