Exhaust manifold - r + r and replace seal

Operation 1072C10 · EXHAUST MANIFOLDS

Removing

Place the vehicle on a lift.

Disconnect the battery negative terminal.

- 7055B54 under-engine guard - r r

- 1080B94 front lambda probe with catalitic converter r r

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1092C10 power steering and/or self-levelling suspension pump drive belt - r + r

1. Undo nuts (1a) securing the reinforcement bracket to the exhaust manifold, undo nut (1b) securing it to the power steering pump mount.

2. Remove the bracket from the engine bay.

Removing

Position the car on the ramp.

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal.

Carry out - 7055B54 under-engine guard - r r.

Carry out - 1064A11 TURBOCHARGER with CATALYTIC CONVERTER - R.R..

1. Undo the fixing bolts (1a) and remove the heat shield (1b) for the engine oil filter cartridge.

Removing

- 1016A22 cam cover with fuel duct - r + r and replace gasket

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 7055B54 under-engine guard - r r

- 1080C50 pipe carrying exhaust gas to e.g.r. valve - r + r

1. Undo the nuts securing the exhaust pipe front section to the corresponding manifold.

Removing

Proceed with the removal - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

Proceed with the removal - 7055B54 under-engine guard - r r.

Proceed with the removal - 1064A19 TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTING HOSE - R.R..

Proceed with the removal - 1064A20 turbo/manifold/sleeve assembly dismantle.

1. Loosen nut (1a) on the catalytic converter band, undo bolts (1b) on the catalytic converter flange.

2. Undo the nuts securing the catalytic converter to the exhaust manifold.

1. Undo the bolts fixing the coolant supply pipe to the engine oil heat exchanger, crankcase side.

2. Undo the bolts fixing the coolant supply pipe to the engine oil heat exchanger, heat exchanger side.

3. Move aside the pipe carrying coolant to the engine oil heat exchanger (3a) complete with seal (3b).

Collect the coolant which comes out in a suitable container.

Lower the lift.

1. Undo the retaining nuts.

2. Remove the exhaust manifold, detaching it from the bolts on the cylinder head.

Refitting

Proceed with the refitting - 1064A20 turbo/manifold/sleeve assembly dismantle.

Proceed with the refitting - 1064A19 TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTING HOSE - R.R..

Proceed with the refitting - 7055B54 under-engine guard - r r.

Proceed with the refitting - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

1. Raise the lift and undo bolts (1a) securing the lower heat shield bracket (1b) and remove.

2. Disconnect the electrical connection for the rear Lambda sensor and move the catalytic converter aside from the exhaust manifold.

1. Undo the nuts (1a) and remove the exhaust manifold (1b).

2. Remove the exhaust manifold gasket.

Refitting

Fit the exhaust manifold onto the corresponding studs.

Tighten the nuts securing the manifold to the cylinder head to the recommended torque.

Raise the lift.

Tighten the nuts securing the exhaust manifold to the front pipe section.

- 1080C50 pipe carrying exhaust gas to e.g.r. valve - r + r

- 1016A22 cam cover with fuel duct - r + r and replace gasket

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 7055B54 under-engine guard - r r

1. Undo the nuts securing the exhaust manifold to the cylinder head.

2. Remove the exhaust manifold.

3. Recover the exhaust manifold seal.

Refitting

1. Place a new exhaust manifold gasket in its seating.

2. Place the exhaust manifold (2a) back in its housing and fix it tightening the nuts (2b) to the recommended torque.

Refitting

Place the exhaust manifold, complete with a new gasket, back in its housing and fix it to the cylinder head tightening the nuts to the recommended torque.

Replace the catalytic converter by securing the studs to the exhaust manifold.

Connect the electrical connection for the rear Lambda sensor.

Position the lower heat shield bracket and tighten the retaining bolts.

Lower the lift and tighten the nuts securing the catalytic converter to the exhaust manifold to the specified torque.

Tighten the bolts securing the catalytic converter to the retaining flange to the specified torque.

Tighten the nut on the catalytic converter retaining band.

Fit the reinforcement bracket to the exhaust manifold and tighten the retaining nuts to the specified torque.

- 1092C10 power steering and/or self-levelling suspension pump drive belt - r + r

- 1092C12 power steering pump drive belt - adjust tension

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1080B94 front lambda probe with catalitic converter r r

- 7055B54 under-engine guard - r r

Connect the battery negative terminal.

Remove the car from the ramps.

Refit in its seating the coolant inlet pipe to the engine oil heat exchanger, complete with gasket, and secure it with the bolts to the engine oil heat exchanger.

Fold back the gasket tabs.

Tighten the coolant inlet hose bolt to the engine oil heat exchanger, crankcase side.

Position the engine oil filter cartridge heat shield in its seating and tighten the fixing bolts.

Carry out - 1064A11 TURBOCHARGER with CATALYTIC CONVERTER - R.R..

Carry out - 7055B54 under-engine guard - r r.

Connect the battery negative terminal.

Remove the car from the ramps.