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Exhaust Manifold with Turbocharger, Remove and
Install
 Remove
Remove air cleaner housing with air intake hose and hot film
mass air flow meter – see illustration "Air Ducts".
For version with AC: Remove ribbed V-belts – see operation
"Ribbed V-belts, Remove and Install".
Remove V-belt – see operation "V-belt, Remove and
Install".
For RHD vehicles: remove alternator – see operation
"Alternator, Remove and Install".
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Detach charge air pipe (3) with charge air hoses from
intercooler and turbocharger. Detach charge air pipe from intake
manifold or bracket and remove.
Detach and remove charge air hose (2) from intercooler, intake
manifold and bracket.
Detach wiring harness plug and vacuum hoses from exhaust gas
recirculation solenoid valve (1).
Remove exhaust gas recirculation solenoid valve from intake
manifold.
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Unclip fuel filter housing (2) from crash box and set aside
– fuel system remains closed.
Detach turbocharger heat shield (1) from return manifold - 3
fastening bolts.
Detach exhaust gas recirculation corrugated metal pipe (5) from
intake manifold and exhaust manifold.
Remove fastening screws (3) for starter heat shield.
Remove lower engine compartment cover – see operation
"Lower Engine Compartment Cover, Remove and Install" in group
"A".
Release fastening nuts (4) for starter heat shield and remove
starter heat shield.
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Detach front exhaust pipe from return manifold - front exhaust
pipe must be prevented from sagging, since bending of even 10 -
15° can cause damage that can lead to total failure of the
flexible pipe!
Detach turbocharger oil return line (1) from upper part of oil
pan – note seal rings – place collecting basin
underneath and close bore hole in oil pan.
Detach turbocharger oil feed line (2) from cylinder block.
Detach exhaust manifold support from exhaust manifold and
release from cylinder block – turn support to one side.
Detach turbocharger oil feed line (3) from turbocharger and
remove.
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Detach exhaust manifold from cylinder head and remove, with
turbocharger, sideways and upwards.
When replacing exhaust manifold: remove fastening bolts (1) and
remove turbocharger from exhaust manifold.
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 Clean
Clean sealing surfaces and remove gasket residues.
Install
When replacing exhaust manifold: attach turbocharger to exhaust
manifold with new gasket – tightening torque – 30 Nm /
22 lbf. ft.
Attach exhaust manifold to cylinder head with new gasket and new
fastening nuts – tightening torque 22 Nm / 16 lbf. ft.
Attach turbocharger oil supply line to turbocharger and
hand-tighten. Attach turbocharger oil supply line to cylinder block
- tightening torque 20 Nm.
Attach turbocharger oil return line to upper part of oil pan
with new seal rings – tightening torque – 45 Nm / 33
lbf. ft.
Attach exhaust manifold support to exhaust manifold and cylinder
block – tightening torque 25 Nm / 18.5 lbf. ft.
Undo retainer and attach front exhaust pipe to return manifold
using new gasket - tightening torque 20 Nm.
Insert starter heat shield and attach with fastening nuts.
Install lower engine compartment cover – see operation
"Lower Engine Compartment Cover, Remove and Install" in group
"A".
Attach heat shield to starter – tightening torque –
6 Nm / 4.5 lbf. ft.
Tighten turbocharger oil feed line – tightening torque
– 30 Nm / 22 lbf. ft.
Attach exhaust gas recirculation corrugated metal pipe with new
gasket to intake manifold and exhaust manifold – tightening
torque – 8 Nm / 6 lbf. ft.
Attach turbocharger heat shield to return manifold –
tightening torque 8 Nm / 6 lbf. ft.
Clip fuel filter housing into crash box.
Attach exhaust gas recirculation solenoid valve to intake
manifold – tightening torque – 8 Nm / 6 lbf. ft.
Attach wiring harness plug and vacuum hoses to exhaust gas
recirculation solenoid valve.
Attach charge air hose to upper part of intake manifold and
intercooler – tightening torque 3.5 Nm / 2.6 lbf. ft.
Attach charge air pipe to charge air cooler and turbocharger -
tightening torque 3.5 Nm.
Attach charge air pipe to intake manifold or bracket –
tightening torque – 3 Nm.
For RHD vehicles: install alternator – see operation
"Alternator, Remove and Install".
Install V-belt – see operation "V-belt, Remove and
Install".
For version with AC: Install ribbed V-belt – see operation
"Ribbed V-belt, Remove and Install".
Install air cleaner housing with air intake hose and hot film
mass air flow meter – see illustration "Air Ducts".
Inspect
Check engine oil level and correct if necessary.
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