Exhaust Manifold Gasket: Service and Repair
Turbocharger (TC), Replacing
Special tools: 999 7076, 999 5562, 999 7057, 951 2953, 951 2957
NOTE: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory Work
Removing Components
Remove:
- the battery negative lead.
- the cross stay between the suspension turrets
- the charge air hose and the charge air pipe above the engine. Remove the hose clamp for the turbocharger (TC) intake pipe at the turbocharger (TC). Pull off the pipe from the connector. Place the pipe to one side. Mark up the vacuum hose for the turbocharger (TC) control valve
- the vacuum hose for the turbocharger (TC) control valve
- the cable for the heated oxygen sensors (HO2S) from the clips and clamps
- the heat deflector plate from the turbocharger (TC).
Draining Coolant
- Raise the vehicle.
- Remove the splash guard under the engine. Open the engine nipple. Drain the coolant into a container. Close the nipple.
Remove:
- the pipe screws for the upper coolant pipe on the turbocharger (TC). Fold the coolant pipe to one side
- the 2 x screws for the oil pressure line on the turbocharger (TC). Disconnect the oil pressure line. Discard the gasket
- the 2 x upper screws between the turbocharger (TC) and the exhaust pipe
- the heated oxygen sensors (HO2S) from the exhaust pipe.
- Remove the three-way catalytic converter (TWC).
Disconnecting The Front Suspension Components
NOTE: Check that the parking brake is not applied. Check the gear selector is in position P.
Remove:
- the right-hand front wheel
- the center screw for the drive shaft.
- the nut for the ball joint and control arm. Counterhold the ball joint pinion so that the boot does not twist. Use a Torx wrench.
NOTE: Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Removing The Drive Shaft
Pull the control arm down. Use: 999 7076. Move the wheel spindle to the side. At the same time, install protective sleeve 999 5562 on the ball joint pinion. Hold the sleeve in place using the nut for the ball joint.
Press out the wheel spindle. Detach the drive shaft from the hub. Do not damage the drive shaft boot. Use a tensioner band to pull the spring strut backwards. Remove the screws from the bearing cap for the drive shaft.
CAUTION: Do not pull the outer part of the shaft. Doing so could damage the axial stops in the joints.
Pull the drive shaft straight out.
Removing The Propeller Shaft
Mark the propeller shaft CV joint in relation to the bevel gear flange.
Remove the screws from the propeller shaft. Use: 999 7057. Press the drive shaft joints together as much as possible. Remove the shaft from the bevel gear. Leave the end of the shaft resting against the anti-roll bar.
Removing Bevel Gear
NOTE: To prevent oil leakage, position the bevel gear with the bleed hole upward.
Remove the 5x screws for the bevel gear. Pull the bevel gear straight out. Then turn it during removal.
Removing Components
Remove:
- the clamp between the turbocharger (TC) oil pressure line and the oil return line
- the screws where the oil return line connects to the turbocharger (TC). Pull the pipe from the cylinder block. Discard the gasket.
NOTE: Check that the rubber sealing ring comes away with the pipe. Seal the opening in the cylinder block.
- the pipe screws where the coolant pipes are connected to the turbocharger (TC)
- the pipe screws for the oil pressure line in the engine block
- the 2x lower nuts for the turbocharger (TC) against the exhaust manifold.
HINT: Use rust solvent or similar
- the upper nuts at the turbocharger (TC) connection for the manifold.
Removing The Turbocharger (TC)
Lift off the turbocharger (TC). Place the turbocharger (TC) on the steering gear. Mark up and remove the turbocharger (TC) hoses. Lower the turbocharger (TC). Discard the old gasket.
Removing The Manifold And Gasket
Remove:
- the inner heat deflector plate from the manifold
- the nuts and washers holding the manifold to the cylinder head
- the manifold
- the old gasket residue. Clean the gasket faces. Check that all the studs are tightened.
NOTE: Ensure that there is no exhaust leakage.
Installing Manifold/Gasket
Install:
- new gaskets
- the manifold. Use new nuts at the manifold. Tighten
- the inner heat deflector plate.
Installing The Turbocharger (TC)
Install:
- the turbocharger (TC) control hoses using the markings made earlier
- the turbocharger (TC) on the manifold using a new gasket
- the upper nuts where the turbocharger (TC) is connected to the manifold. Tighten
- the inlet hose for the intake pipe on the turbocharger (TC). Tighten the hose clamp
- the 2x screws for the oil pressure pipe. Use a new gasket. Tighten
- the pipe screws to the upper coolant pipe. Tighten.
Raise the vehicle.
- the 2x lower screws between the turbocharger (TC) and manifold. Tighten
- the oil return line in the cylinder block with a new sealing ring
- the 2x screws for the oil return line in the turbocharger (TC). Use a new gasket. Tighten
- the pipe screws for the lower coolant pipe. Use new copper washers. Tighten
- the pipe screws for the lower oil pressure line in the engine block. Use new copper washers. Tighten
- the clamp between the turbocharger (TC) oil pressure line and the oil return line. Tighten.
Installing The Bevel Gear
Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear. Use grease.
Ensure that the mating surfaces on the transmission and bevel gear are clean. Install the bevel gear. Lightly tighten the M10 screws alternately. Tighten.
Installing The Propeller Shaft
Check that the mating surfaces of the propeller shaft and flange are clean. Install the propeller shaft using the marking made earlier. Use new screws. Tighten.
Install the three-way catalytic converter (TWC).
Installing The Drive Shaft And Bearing Cap On The Pilot Bearing For The Shaft
Tighten the screws.
Installing The Drive Shaft
NOTE: Check that the seal on the end of the drive shaft is correctly positioned.
Press out the spring strut.
Align the drive shaft in the hub.
Remove the protective sleeve 999 5562.
Locate the control arm on the ball joint pinion. Use: 999 7076.
Install:
- the nut for the ball joint and control arm. Tighten. Counterhold so that the ball joint boot does not rotate. Use a Torx wrench
- the drive shaft center screw. Use a new screw. Tighten. Use a screwdriver as a counterhold on the brake disc.
Fitting The Wheel
Install the wheel.
Installing Components
Install:
- the screws for the heat deflector plate above the turbocharger (TC) and the screws for the oil pressure line. Tighten
- the pipe screws for the upper coolant pipe. Tighten
- the upper charge air pipe. Tighten the screws and clamps
- the engine stabilizer brace between the suspension turrets. Tighten the 5 screws
- the battery negative lead.
Finishing
Checks
- Fill with coolant. Use filling equipment: 951 2957 and cover 951 2953.
- Check the oil level in the engine and transmission. Start the engine and run the engine to normal operating temperature.
- Check for any leakage.
- Fill with fluids if necessary.