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Rear exhaust manifold, V6

Rear exhaust manifold, V6

To remove


1. Note the radio code if applicable, remove the battery cover and undo the positive cable on the battery.


2. Remove the upper engine cover and the air inlet to the generator.

3. Detach the oxygen sensor connectors from the holder on the rear SAI valve by releasing the catch and pushing them down.

4. Undo the SAI pipe mounting on the cylinder head. Undo the connections to the exhaust manifold.


5. Undo the hose connections for the SAI valve and remove the pipe with valve.

6. Undo the two outer nuts on the rear exhaust manifold.

7. Raise the car.

8. Detach the front pipe from the front and rear exhaust manifold. Secure the front exhaust pipe with a cable tie, 83 95 212 Cable tie .

Important

The flexible section at the front of the exhaust system should not be bent out of line by more than 7°, i.e. if the front exhaust system is allowed to hang, it must not bend more than the sag caused by its own weight.

If the pipe is overloaded, permanent deformation of the components will result. This can cause noise and leakage, and damage at a later stage.



9. Undo the two lower nuts on the rear exhaust manifold.


10. Lower the car to the floor.

11. Undo the three upper nuts on the rear exhaust manifold and remove the exhaust manifold.


To fit

Note

Smear the studs and gaskets sparingly with Molycote 1000, part. no. 30 20 971 or similar, to prevent them baking on.



1. Clean the sealing surfaces and fit a new gasket for the rear exhaust manifold. Fit the rear exhaust manifold.


2. Fit the three upper nuts on the rear exhaust manifold.

Tightening torque: 20 Nm (14.7 lbf ft).

3. Raise the car.

4. Fit the two lower nuts on the rear exhaust manifold.

Tightening torque: 20 Nm (14.7 lbf ft).

5. Fit a new gasket between the front exhaust pipe and rear exhaust manifold.

6. Fit the front exhaust pipe to the front and rear exhaust manifolds.

Tightening torque:

Turbo, locknuts: 24 Nm (17.7 lbf ft)

Rear exhaust manifold: 40 Nm (29.5 lbf ft)

7. Lower the car to the floor.

8. Fit the two outer nuts on the rear exhaust manifold.

Tightening torque: 20 Nm (14.7 lbf ft).


9. Attach the hose connection to the SAI pipe and check the connection.

10. Fit the SAI pipe with new gaskets to the exhaust manifold and cylinder head.

11. Fasten the oxygen sensor connectors to the holder.


12. Fit the air intake to the generator and the upper engine cover.

13. Connect the positive cable to the battery, fit the battery cover, adjust the clock and set the radio code if applicable.