Remove/install exhaust manifold with catalytic converter

AR14.10-P-4095V

Remove/install exhaust manifold with catalytic converter

21.2.08

18.2.08

Nut, exhaust manifold to cylinder head

Engine 271

*BA14.10-P-1001-01E

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Danger!

Risk of injury from grazing 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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

1

Raise vehicle

AR00.60-P-1000V

2

Detach rear part of the lower engine compartment paneling

 Installation: Install engine compartment paneling only after engine test run.

AR61.20-P-1105V

3

Remove bracket (1) of exhaust manifold with catalytic converter (2)



*BA49.10-P-1010-01K



*BA49.10-P-1011-01K

4

Remove O2 sensor downstream of CAT (G3/1)

AR07.52-P-5303V

5

Unclip connector for O2 sensor upstream of CAT (G3/2x1) from the holder (3) and disconnect

 Unclip electrical line from the brackets.

6

Detach exhaust manifold with catalytic converter (2) from underfloor catalytic converter (4), for this step unscrew bolts (5)

 Installation: Clean connection points from combustion and corrosion residues, replace bolts (5).

Check rivet nuts in the exhaust manifold with catalytic converter (2), replace if required: 

Replace rivet nuts in exhaust manifold.

AR49.10-P-5531-01DA



*BA49.10-P-1012-01K



*103589013900

7

Remove bolts (12) and remove heat shield (6) from exhaust manifold with catalytic converter (2)



*BA49.10-P-1017-01K



*001589760900

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

8

Open engine hood

AR88.40-P-1000V

9

Remove heat shield (7)



*BA05.20-P-1004-03A



*001589760900

10

Unclip terminal 61 (D+) (8) electrical line at the heat shield of power steering pump (9)

11

Remove bolt (13) and take out shield (14)



*BA22.10-P-1004-01O

12

Detach exhaust manifold with catalytic converter (2) from cylinder head by unscrewing nut (10)

 Installation: Install new nuts. (10).



*BA14.10-P-1001-01E

13

Remove exhaust manifold with catalytic converter (2)

 Installation: Clean sealing surfaces and replace gasket (11).

14

Remove O2 sensor upstream of CAT from exhaust manifold with catalytic converter (2)

 When replacing the exhaust manifold with catalytic converter (2).

AR07.52-P-5303V

15

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

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

AS00.00-Z-0005-01A

16

Test run engine and check exhaust system for leaks

Number

Designation

Engine
271
in model
171

BA49.10-P-1010-01K

Bolt connecting exhaust manifold with catalytic converter to bracket

Nm

20

BA49.10-P-1011-01K

Bolt, catalytic converter bracket to transmission

Nm

40

BA49.10-P-1012-01K

Bolt connecting underfloor catalytic converter to exhaust manifold with catalytic converter

Nm

20

BA49.10-P-1017-01K

Bolt connecting heat shield to exhaust manifold with catalytic converter

Nm

8

Number

Designation

Engine 271

BA05.20-P-1004-03A

Shield to camshaft bearing housing

M6

Nm

8

Number

Designation

Engine
271 in model 171

BA22.10-P-1004-01O

Bolt connecting front engine mount to engine support

Nm

50

Number

Designation

Engine
271

BA14.10-P-1001-01E

Nut, exhaust manifold to cylinder head

Nm

21