Volkswagen Workshop Service and Repair Manuals

Removing and installing exhaust manifold Special tools and workshop equipment required

t  Ring spanner set for lambda probe -3337-   Note t  Vehicles with engine codes BLY and BVZ comply with emission standard EU 2. On these vehicles some components which are relevant for exhaust emissions are not fitted, e.g.: exhaust gas recirculation system NOx sensor control unit -J583-, Lambda probe 2 -G108- and Lambda probe 2 after catalytic converter -G131-. Take note when performing work sequences. t  The exhaust manifold is removed from above. Removing exhaust manifold –  Remove noise insulation → General body repairs, exterior; Rep. Gr.50.

–  Remove securing nuts -arrows- for front exhaust pipe to exhaust manifold.   Note The flexible joint in front exhaust pipe must not be bent more than 10° - danger of damage.

–  Unscrew bracket for exhaust system -arrows-.

–  Remove bolts -1…3- for exhaust manifold support.

–  Remove engine cover, if fitted -arrows-.

–  Remove connectors -1 and 2- for Lambda probes from retainer and separate.   Note Engine code BVY only with one connector.

–  Unclip coolant hose -1- and pull off connector -2-. Engine codes AXW, BLR, BLX and BVX: –  Remove cable guide → Item. Continuation for all vehicles:

–  Unscrew securing bolts -1 and 2-. –  Then loosen bolts on intake manifold and remove connecting pipe.

–  Free wiring harness for Lambda probe -arrows-. –  Remove lambda probe-1-.   Note The coolant hoses for exhaust gas recirculation valve -N18- remain connected.

–  Remove exhaust gas recirculation valve -N18--arrows- and lay to side.

–  Remove heat shield above exhaust manifold by removing bolts -1- and pulling off heat shield -arrows-.

–  Remove exhaust manifold -arrow- and take out upwards. Installing exhaust manifold: Installation is carried out in the reverse order. When installing, note the following: t  Reinstall all cable ties in the same locations when assembling. t  Coat studs of cylinder head and exhaust manifold with high-temperature paste. t  Renew self-locking nuts when performing assembly work. t  Renew all seals and gaskets. t  Lubricate the threads of the Lambda probe with high-temperature paste. The paste must not penetrate into the slots on the probe body. Specified torques:

Component		Nm
Exhaust manifold to cylinder head		25 → Note
Heat shield to exhaust manifold		10
Lambda probe		55 → Note
Exhaust system mounting to sub-frame		25
Front exhaust pipe to exhaust manifold		25 → Note
EGR connecting pipe to exhaust gas recirculation valve		10
EGR connecting pipe to exhaust manifold		15

1)  Coat cylinder head studs, exhaust manifold studs and Lambda probe thread with high-temperature paste → ETKA (electronic parts catalogue). 2)  Renew self-locking nuts.