Exhaust manifold, 4-cyl.
Exhaust manifold, 4-cyl. |
To remove |
|
1. |
Open the expansion tank cap to release the system pressure.
|
2. |
Raise the car.
|
3. |
Remove the lower front cover.
|
4. |
Drain off the coolant.
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5. |
Undo the bolt at the turbo mounting on the engine block.
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6. |
Loosen the upper screw on the turbo mounting.
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7. |
Detach the turbo return hose to the sump.
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8. |
Loosen the oil pipe to the turbo at the oil filter adapter.
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9. |
Lower the car to the floor.
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10. |
Remove the bypass pipe and valve.
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11. |
Remove the exhaust manifold's heat shield.
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12. |
Unplug the radiator fan's connectors and move them aside.
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13. |
Remove the bolts on each side of the fan assembly.
|
14. |
Loosen the clip holding the cooling system vent hose.
On cars with automatic transmission, also remove the pipe mounting on the fan cowling. |
15. |
Detach the upper radiator hose by undoing the hose clip and bending the hose aside.
|
16. |
Unhook and twist the fan assembly, then lift it out.
|
17. |
Unplug the boost pressure control valve connector.
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18. |
Unplug the mass air flow sensor connector.
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19. |
Detach the crankcase breather pipe fastened to the turbo intake pipe and detach the camshaft cover.
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20. |
Bend the pipe and wiring aside.
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21. |
Remove the mass air flow sensor and air hose.
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22. |
Loosen the hoses to the turbo and the diaphragm box.
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23. |
Unplug the quick-release coupling on the purge hose with
83 95 261 Tools, Fuel line
.
|
24. |
Undo the intake pipe's V-clamp at the turbo.
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25. |
Unbolt the intake pipe from the power steering pump mounting.
|
26. |
Lift out the intake pipe.
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27. |
Disconnect the hose clip on the hose between the turbo and charge air cooler. Plug the hose to keep it clean using a plug
83 94 595 Plug, turbo hose
or something similar.
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28. |
Undo the retaining nuts and remove the front part of the exhaust system from the turbo.
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29. |
Carefully lower the front exhaust system away from the turbo.
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30. |
Remove the oil pipe to the turbo. Save the copper washers.
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31. |
Loosen the water pipe at the turbo. Save the copper washers.
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32. |
Release the water pipe screw at the coolant pump.
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33. |
Loosen the water return pipe from the turbo at the cylinder head and the pressure sensor mounting. Save the copper washers.
|
34. |
Undo the water return pipe's bolt at the turbo.
|
35. |
Remove the bolts securing the turbo to the exhaust manifold.
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36. |
Relieve the tension on the multigroove belt with a puller shank
83 95 254 Puller shank, hydraulic belt tensioner
.
|
37. |
Move the belt away from the power steering pump.
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38. |
Remove the power steering pump bracket from the engine mount.
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39. |
Undo the power steering pump bracket bolts and move the pump aside.
|
40. |
Push the turbo aside and remove the exhaust manifold. Save the spacer sleeves and washers.
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To fit |
Note | ||
Smear the studs and gasket sparingly with Molycote 1000, part. no. 30 20 971 or similar, to prevent them baking on. |
||
Spray the connectors with Kontakt 61, part no. 30 04 520. |
1. |
Fit a new gasket to the exhaust manifold.
|
2. |
Fit the exhaust manifold.
|
3. |
Fit the washers, spacers and nuts.
Tightening torque: 25 Nm (18.4 lbf ft) |
4. |
First fit the top left bolt in the power steering pump bracket. Then fit the other two bolts.
Tightening torque: 24 Nm (17.7 lbf ft). |
5. |
Bolt the power steering pump bracket to the engine mount and tighten the bolts.
Tightening torque: 24 Nm (17.7 lbf ft). |
6. |
Attach the multigroove belt and adjust the belt tensioner. Use a puller shank
83 95 254 Puller shank, hydraulic belt tensioner
.
|
8. |
Fit the front part of the exhaust system to the turbo and tighten the nuts.
Tightening torque: 24 Nm (17.7 lbf ft).
|
9. |
Fit the turbo water return pipe. Use new copper washers.
Tightening torque: Water return pipe/cylinder head: 25 Nm (18.4 lbf ft) Water return pipe/turbo: 25 Nm (18.4 lbf ft) |
10. |
Fit the turbo water pipe. Tighten the pipe also at the coolant pump end. Use new copper washers.
Tightening torque: Water pipe/turbo 25 Nm (18.4 lbf ft) Water pipe/coolant pump: 20 Nm (14.7 lbf ft) |
11. |
Fit and tighten the turbo oil pipe at the turbo. Use new copper washers.
Tightening torque: Oil pipe to turbo/turbo: 20 Nm (14.7 lbf ft) |
12. |
Fit a new O-ring greased with non-acidic vaseline to the turbo intake pipe. Slide the V-clamp on the pipe and position same. Bolt the pipe to the power steering pump bracket to facilitate tightening/fitting the V-clamp.
|
13. |
Slacken the adjusting screw on the intake pipe to adjust the pipe.
|
14. |
Tighten the intake pipe bolt on the power steering pump bracket. Also tighten the adjusting screw.
Tightening torque: 24 Nm (17.7 lbf ft). |
15. |
Tighten the V-clamp between the turbo and the turbo intake pipe.
Tightening torque: 3 Nm (2.2 lbf ft) |
16. |
Connect the hoses to the diaphragm box and turbo, and the vent hose.
|
17. |
Remove the plug from the charge air cooler intake pipe.
|
18. |
Connect the charge air cooler intake pipe to the turbo.
Tightening torque: 8 Nm (5.9 lbf ft) |
19. |
Fit the heat shield. Press the left clip on first. Coat the nut with Molycote 1000, part no. 30 20 971.
Tightening torque: 20 Nm (14.7 lbf ft). |
20. |
Fit the fan assembly. Ensure that it is positioned on the lower hooks. Tighten the two bolts on the sides of the fan assembly.
Tightening torque: 8 Nm (5.9 lbf ft) |
21. |
Plug in the fan assembly's connectors.
|
22. |
Fit the clip that holds the cooling system vent hose.
On cars with automatic transmission, also attach the pipe mounting on the fan cowling. |
23. |
Fit the upper radiator hose.
|
24. |
Fit the mass air flow sensor and air hose.
|
25. |
Fit the crankcase breather pipe to the camshaft cover and turbo intake pipe.
Tightening torque: 24 Nm (17.7 lbf ft).
|
26. |
Plug in the mass air flow sensor and boost pressure control valve connectors.
|
27. |
Connect the bypass pipe and valve. Use a new O-ring lubricated with acid-free petroleum jelly (vaseline).
|
28. |
Tighten the bypass pipe screw and hose clamp.
Tightening torque: 8 Nm (5.9 lbf ft) |
29. |
Raise the car.
|
30. |
Connect the turbo oil return hose to the sump.
|
31. |
Fit and tighten the turbo oil pipe at the oil filter adapter.
Tightening torque: 25 Nm (18.4 lbf ft) |
32. |
For the turbo mounting.
Tightening torque: 24 Nm (17.7 lbf ft). |
33. |
Lower the car to the floor.
|
34. |
Check that the radiator drain cock is closed. Fill with coolant. For the correct mixture, see “Cooling system”, Technical Data
. Close the radiator cap.
|
35. |
Start the car.
|
36. |
Set the heater control at full heat.
|
37. |
Warm up the engine to expel any air from the cooling system.
|
38. |
Raise the car and check for oil and water leaks.
|
39. |
Fit the lower front cover.
|
40. |
Lower the car to the floor.
|
41. |
Top up with coolant/oil as necessary.
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