Exhaust Manifold: Service and Repair

Exhaust manifold / gasket, replacing

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.

Removing manifold / gasket





Remove
- the screw for the engine stabilizer brace
- the screws for the mounting for the engine stabilizer brace at the right-hand suspension turret
- the heat deflector plate over the manifold.
Place the air preheating hose to one side.





Remove
- the left front wheel
- the clamp for the mounting for the heated oxygen sensor wiring at the steering gear
- the splash guard under the engine.
Release the wiring for the heated oxygen sensor (HO2S) from the rear engine mounting
- the nuts at the junction of the manifold and the front exhaust pipe.





Lower the front exhaust system
Remove the screws holding the SIPS member to the bodywork.
Press the brake pipe out of the holders on the SIPS member.
Press the exhaust system backwards. Remove the exhaust system from the manifold.
Do not damage the heated oxygen sensors (HO2S) or the wiring.

Note! The metal hose for the front exhaust pipe is very easily damaged. Therefore it should be handled with great care to avoid leakage later.





Remove
- the nuts holding the manifold to the cylinder head.
Raise the engine stabilizer brace. Remove the manifold
- the gaskets.
Clean the gasket faces. Check that the studs are tightened.

Installing the manifold / gasket

Note! For tightening torques, see: Tightening torque Tightening Torque.

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.




Lubricate the studs at the cylinder head and manifold. Use paste (P/N 116 14 08). Avoid skin contact with the paste!
Install new gaskets.
Hold the manifold in place. Install new nuts. Tighten to 25 Nm.





Install
- the front exhaust pipe on the manifold. Use a new gasket and new nuts. Do not tighten!
- the screws securing the SIPS member to the bodywork
- the brake pipe in the holders at the SIPS member.
Tighten the nuts at the junction of the manifold and the front exhaust pipe. Tighten the screws securing the SIPS member. Tighten to 25 Nm.
Secure the wiring for the heated oxygen sensors (H02S) at the rear engine mounting and at the steering gear.
- the left-hand front wheel. See Installing wheels Service and Repair
- the splash guard under the engine.




- the heat deflector plate over the manifold
- the air pre-heating hose
- the screws for the mounting for the engine stabilizer brace at the right-hand suspension turret. Tighten to 50 Nm
- the screw for the engine stabilizer brace. Tighten to 80 Nm.

Check
Test run the engine. Note any exhaust leakage.