Remove/install right exhaust manifold

AR14.10-S-3008PS

Remove/install right exhaust manifold

27.07.2018

Engine

642 in model 470, 471

Shown with engine removed

1

Exhaust manifold

2

Screw

3

Electrical wiring harness

4

Oxygen sensor upstream of catalytic converter

5

Bolts

6

Exhaust pipe

7

Exhaust collector pipe

8

Seal

Shown with engine removed

1

Exhaust manifold

7

Exhaust collector pipe

9

Bolts

Shown with engine removed

10

Nut

12

Bracket

11

Bolts

13

Heat shield

Shown with engine removed and exhaust gas turbocharger removed

1

Exhaust manifold

15

Bracket

8

Seal

16

Nuts

14

Nuts

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove front wheel.

AR40.10-S-1100P

 Installation: Only attach front wheel again after leak test.

2

Remove front fender liner.

AR88.10-S-1301P

 Installation: Only reinstall fender liner after leak test.

3

Remove the transmission with torque converter.

AR27.10-S-0500PS

4

Remove right air filter housing.

AR09.10-S-1150PS

5

Expose and disconnect electrical wiring harness (3) of lambda sensor upstream of catalytic converter (4).

6

Remove screw/bolt (2).

 Installation: Replace screw/bolt (2).

 Bolt, exhaust pipe to turbocharger

*BA09.40-N-1012-01Q

7

Remove screws (5) and remove exhaust pipe (6) with lambda sensor upstream of catalytic converter (4).

 Installation: Replace screw/bolts (5).

 Bolt, exhaust pipe to turbocharger

*BA09.40-N-1012-01Q

8

Remove screws/bolts (9).

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 Screw/bolt, flange connection of exhaust manifold/front exhaust pipes to exhaust collector pipe

*BA14.10-N-1003-01O

9

Unscrew nut (10).

10

Remove screws (11).

11

Slightly lift bracket (12) and remove heat shield (13).

12

Unscrew nuts (14).

 Installation: Replace nuts(14).

 Nut, exhaust manifold to cylinder head

*BA14.10-N-1001-01O

13

Remove bracket (15).

14

Unscrew nuts (16).

 Installation: Replace nuts (16).

 Nut, exhaust manifold to cylinder head

*BA14.10-N-1001-01O

15

Remove exhaust manifold (1).

16

Remove seal between exhaust manifold (1) and cylinder head.

 Installation: Replace seal.

17

Remove seal (8).

 Installation: Install new seal (8).



Check

18

Check all stud bolts of exhaust manifold (1) for damage.

If there is a problem,



Replace corresponding stud bolt.

 Stud bolt, exhaust manifold to cylinder head

*BA14.10-N-1002-01O



Clean

19

Clean sealing surfaces on cylinder head.

20

Clean sealing surfaces on exhaust manifold (1).

If exhaust manifold (1) is not replaced.

21

Clean sealing surface on exhaust gas collector pipe (7).

22

Install in the reverse order.



Check

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

23

Perform engine test run and check exhaust system for leaks in repair area in the process.

 Turbocharger

Number

Designation

Engine 642 in model 470, 471

BA09.40-N-1012-01Q

Bolt, exhaust pipe to turbocharger

Nm

20

 Exhaust manifold

Number

Designation

Engine 642 in model 470, 471, 639

BA14.10-N-1001-01O

Nut, exhaust manifold to cylinder head

Stage 1

Nm

25

Stage 2

Nm

-

 Exhaust manifold

Number

Designation

Engine 642 in model 470, 471, 639

BA14.10-N-1002-01O

Stud bolt, exhaust manifold to cylinder head

Nm

20

 Exhaust manifold

Number

Designation

Engine 642 in model 470, 471, 639

BA14.10-N-1003-01O

Screw/bolt, flange connection of exhaust manifold/front exhaust pipes to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90