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Exhaust manifold, ch no 12020001-

Exhaust manifold, ch no 12020001-

Warning

There is a risk of burn injuries when working with the exhaust pipe.


To remove


1. Lay out wing covers and remove the negative cable from the battery.

2. Remove the engine cover and the charge air pipe (2 screws under the wiring harness). Seal the hoses.


3. Remove mountings from camshaft cover.

4. Remove the electric connections from the glow plugs.

5. Remove crankcase breather hose and intake hose from the turbocharger.

6. Remove heat shields from turbocharger, exhaust manifold and starter. Release one of the bolts on the lifting eye for clearance. The lower heat shield fixing to the starter need merely be loosened.


7. Remove the wiring harness duct from the engine and move it forward.

8. Remove the nuts securing the front exhaust pipe to the turbocharger.

9. Raise the car and remove the lower cover.


10. Loosen the joint between the front exhaust pipe and the middle pipe.


11. Remove the front rubber mountings and lower the exhaust pipe.

Important

Work carefully so that the bellows is not bent or cracked.


12. Position a container underneath the engine and remove the oil delivery pipe for the turbocharger from the cylinder block.


13. Remove the oil return pipe for the turbocharger from the cylinder block.

14. Remove the upper bolt for the exhaust manifold bracket and loosen the lower bolt so that the bracket can be twisted aside. Lower the car.

15. Release the vacuum hose from the control valve membrane unit, remove the exhaust manifold and lift out the turbo unit with manifold.

16. Remove the turbocharger from the exhaust manifold.


To fit


1. Clean the sealing surfaces, apply Molycote 1000 on the sealing surfaces and on the studs, fit the turbocharger on the exhaust manifold.

Tightening torque 30 Nm (22 lbf ft).


2. Clean the sealing surfaces, apply Molycote 1000 on the studs and fit the exhaust manifold to the cylinder head using a new gasket and new nuts.

Tightening torque 22 Nm (16 lbf ft).

3. Connect the vacuum hose to the idle air control valve diaphragm box.

4. Apply Molycote 1000 on the turbocharger studs.

5. Raise the car. Twist the exhaust manifold support back into place and tighten the bolts.

Tightening torque 25 Nm (18.5 lbf ft).

6. Connect the turbocharger oil return pipe to the cylinder block.

Tightening torque 30 Nm (22 lbf ft).

7. Connect the oil delivery pipe for the turbocharger to the cylinder block.

Tightening torque 20 Nm (15 lbf ft).

8. Clean the exhaust pipe joints and fit new rubber mountings if needed.


9. Fit the front part of the exhaust pipe using a new gasket and fit new nuts.

10. Tighten the exhaust pipe to the middle pipe.

Tightening torque 20 Nm (15 lbf ft).

11. Fit the cover and lower the car.


12. Tighten the nuts between the turbocharger and the front exhaust pipe.

Tightening torque 20 Nm (15 lbf ft).


13. Remove the oil delivery pipe connection from the turbocharger and fill the turbocharger oil channel with engine oil. Turn the turbocharger shaft a few times and top up if needed.

Important

It is essential that there is oil in the turbocharger when the engine is started.


14. Tighten the oil delivery pipe connector to the turbocharger using new sealing washers.

Tightening torque 20 Nm (15 lbf ft).

15. Refit the wiring harness duct to the engine.

16. Refit the heat shields over the exhaust manifold, turbocharger and starter. Tighten the bolt on the lifting eye.

17. Connect the intake hose to the turbocharger and the hose to the crankcase ventilation.


18. Connect the glow plugs.

19. Refit the bracket on the camshaft cover.

20. Fit the charge air pipe.

21. Fit the engine cover.

22. Connect the negative cable to the battery.

23. Adjust the clock in the car and press 5 times on the remote control lock/unlock button.

24. Check the oil level and top up if needed.

25. Start the engine and check for leakage.