Front exhaust manifold, V6
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Front exhaust manifold, V6
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Important
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The oxygen sensor cable must not be of twisted type. Twisted cables exposed to vibration can break.
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The oxygen sensor is sensitive to impacts and jolting and must be handled with care.
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1.
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Position the car on a lift.
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2.
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Remove the upper engine cover.
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3.
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Remove the turbo pressure hose together with the turbo bypass pipe and valve.
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4.
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Plug the charge air cooler's outlet.
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5.
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Remove the exhaust manifold's heat shield.
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6.
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Loosen the crankcase ventilation pipe between the turbo intake pipe (watch out for the sealing washers) and the cylinder head and the hose from the oil trap.
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7.
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Detach the turbo intake pipe. Bend the pipe aside.
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8.
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Detach the turbo's outlet hose to the charge air cooler.
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9.
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Remove the radiator fan. See “Cooling system, Adjustment, Replacement”
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10.
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Pinch the inlet and return water hoses to the turbo. Use the pinch-off pliers, part no. 30 07 739.
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11.
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Remove the water pipes to the turbo.
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12.
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Undo and remove the dipstick tube.
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13.
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Remove the front pipe from the turbo.
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14.
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Unplug the oxygen sensor's connector.
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16.
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Snip the cable tie securing the oxygen sensor cable. Note the way the cable is run and lower the cable.
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17.
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Separate the pipe joint between the front and rear exhaust systems.
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Note
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Removal of the front exhaust system will be easier if a cable tie, part No. 83 95 212, is fastened round the front pipe.
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18.
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Detach the front pipe from the rear exhaust manifold. Lower away the front exhaust system.
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19.
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Remove the turbo's oil return pipe.
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20.
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Remove the turbo mounting bracket.
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21.
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Detach the oil pipe from the oil filter adapter.
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22.
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Lower the car to the floor.
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23.
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Undo the nuts securing the front exhaust manifold.
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24.
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Remove the front exhaust manifold with turbo.
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Important
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The oxygen sensor cable must not be of twisted type. Twisted cables exposed to vibration can break.
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The oxygen sensor is sensitive to impacts and jolting and must be handled with care.
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Note
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Smear the studs and gaskets sparingly with Molycote 1000, part. no. 30 20 971 or similar, to prevent them baking on.
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Note
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Spray the connector with Kontakt 61, part no. 30 04 520, before plugging it in.
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1.
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Fit a new gasket for the front exhaust manifold.
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2.
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Fit the front exhaust manifold with turbo.
Tightening torque: 20 Nm (14.7 lbf ft).
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Important
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It is essential that there is oil in the turbo bearing housing when the engine is started.
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Fill the turbo oil inlet with oil from an oilcan. Rotate the compressor by hand many times so that the oil penetrates into the bearings.
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4.
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Fit a new gasket on the front pipe against the rear exhaust manifold.
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Note
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Removal of the front exhaust system will be easier if a cable tie, part No. 83 95 212, is fastened round the front pipe.
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5.
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Fit the front exhaust pipe to the rear exhaust manifold.
Tightening torque: 40 Nm (29.5 lbf ft).
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6.
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Fit the pipe joint between the front and rear exhaust systems.
Tightening torque: 22 Nm (16.2 lbf ft).
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7.
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Use a cable tie to secure the oxygen sensor cable. Carefully run the cable back to the oxygen sensor connector.
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8.
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Fit the oil pipe to the oil filter adapter. Fit new gaskets and sealing washers.
Tightening torque: 20 Nm (14.7 lbf ft).
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9.
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Fit the turbo mounting bracket.
Tightening torque: 24 Nm (17.7 lbf ft).
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10.
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Fit the turbo's oil return pipe.
Tightening torque:
M6 bolt: 14 Nm (10.3 lbf ft)
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11.
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Lower the car to the floor.
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12.
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Plug in the oxygen sensor connector.
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13.
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Bolt the front exhaust pipe to the turbo.
Tightening torque: 24 Nm (17.7 lbf ft).
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14.
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Fit the dipstick tube.
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15.
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Fit the turbo water return pipe. Use new seal washers.
Tightening torque:
Banjo bolt, turbo 25 Nm (18.4 lbf ft)
Retaining screw cylinder head 14 Nm (10.3 lbf ft)
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16.
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Remove the pinch-off pliers from the inlet and return water hoses to the turbo.
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17.
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Fit the radiator fan. See “Cooling system, Adjustment, Replacement”
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Tightening torque: 8 Nm (5.9 lbf ft)
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18.
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Fit the hose between the turbo and the charge air cooler.
Tightening torque: 8 Nm (5.9 lbf ft)
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19.
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Fit the turbo's intake pipe.
Tightening torque:
V-clamp 3 Nm (2.2 lbf ft)
U-clamp cylinder head 14 Nm (10.3 lbf ft)
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20.
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Fit the crankcase breather pipe between the cylinder head and turbo intake pipe. Change the sealing washers. Connect the hose from the oil trap.
Tightening torque:
Banjo bolt, intake pipe: 24 Nm (17.7 lbf ft)
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21.
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Remove the plug from the charge air cooler outlet.
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22.
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Fit the front exhaust manifold's heat shield.
Tightening torque: 24 Nm (17.7 lbf ft).
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23.
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Fit the turbo pressure hose together with the turbo bypass pipe and valve.
Tightening torque: 8 Nm (5.9 lbf ft)
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24.
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Start the engine and check for oil and water leakage.
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25.
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Switch off the engine and check oil and water levels. Top up as necessary.
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26.
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Fit the upper engine cover.
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