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Exhaust Heat Shield Replacement - Diesel and Petrol > < Exhaust Manifold Heat Shield Replacement - 1.7L Diesel LPL, LPV, LUD, LUE, LKR

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Exhaust Manifold Replacement (1.7L Diesel LPL, LPV, and LUB)

Removal Procedure

Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Warning: Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.

Caution: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage the exhaust flex decoupler.

1. Open the hood.
2. Remove the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .

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3. Remove the radiator outlet hose clamp (2).
4. Remove the radiator outlet hose (3) from the coolant pipe (1).

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5. Remove the radiator surge tank hose clamp (3).
6. Remove the radiator surge tank hose (2) from the coolant pipe (4).
7. Remove the vacuum hose (5) from the turbocharger wastegate actuator (6).
8. Remove the turbocharger oil feed pipe bolt (1) in conjunction with the 2 seal rings (7, 9).
9. Put the turbocharger oil feed pipe (8) aside.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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11. Remove the exhaust pressure sensor hose (2) from the exhaust pressure sensor pipe (3).
12. Disconnect the heated oxygen sensor wiring harness plug (1).
13. Remove the heated oxygen sensor wiring harness retainer (4) from bracket.

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14. Remove the 3 exhaust front pipe nuts (3).
15. Remove the exhaust front pipe (2) from the catalytic converter (4).
16. Remove and DISCARD the old exhaust front pipe gasket (1).

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17. Remove the 2 catalytic converter bracket bolts (2) from the catalytic converter bracket (1).

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18. Remove the 2 charge air cooler inlet air hose bolts (4).
19. Remove the charge air cooler inlet air pipe (3) from the turbocharger (1).
20. Remove and DISCARD the charge air cooler inlet air pipe gasket (2).

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21. Loosen the 2 turbocharger oil return hose clamps (1, 3).
22. Remove the turbocharger oil return hose (2) from the turbocharger (4).

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23. Remove the 7 exhaust manifold nuts (3) and the washers.
24. Remove the 2 exhaust manifold bolts (4) and the washers.
25. Remove the exhaust manifold in compound with the turbocharger (2) and the catalytic converter.
26. Remove and DISCARD the exhaust manifold gasket (1).

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27. Remove the 3 catalytic converter heat shield bolts (3, 4).
28. Remove the catalytic converter heat shield (2) from the turbocharger (1).

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29. Remove the 3 catalytic converter bolts (4).
30. Remove the catalytic converter (3) from the turbocharger (1).
31. Remove and DISCARD the catalytic converter gasket (2).

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32. Remove the 3 turbocharger nuts (3, 5).
33. Remove the turbocharger (4) from the exhaust manifold (1).
34. Remove and DISCARD the turbocharger gasket (2).

Installation Procedure


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1. Install a NEW turbocharger gasket (2).
2. Install the turbocharger (4) to the exhaust manifold (1).

Caution: Refer to Fastener Caution .
3. Install 3 NEW turbocharger nuts (3, 5) and tighten in two passes:
  •  First pass tighten to 24 N·m (18 lb ft)
  •  Second pass tighten to 48 N·m (35 lb ft)

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4. Install a NEW catalytic converter gasket (2).
5. Install the catalytic converter (3) to the turbocharger (1).
  Install the 3 NEW catalytic converter bolts (4) and tighten to 45 N·m (33 lb ft) .

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6. Install the catalytic converter heat shield (2) to the turbocharger (1).
7. Install the 3 catalytic converter heat shield bolts (3, 4) and tighten to 10 N·m (89 lb in) .

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8. Clean the sealing surfaces.
9. Install a NEW exhaust manifold gasket (1).
10. Install the exhaust manifold (2) in compound with the turbocharger.
11. Loosely install the washers and the 7 NEW exhaust manifold nuts (3).
12. Loosely install the washers and the 2 NEW exhaust manifold bolts (4).

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13. Tighten the exhaust manifold nuts and the exhaust manifold bolts in the tightening sequence as shown to 69 N·m (51 lb ft) .

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14. Install the turbocharger oil return hose (2) to the turbocharger (4).
15. Reposition and tighten the 2 turbocharger oil return hose clamps (1, 3).

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16. Install a NEW charge air cooler inlet air pipe gasket (2).
17. Install the charge air cooler inlet air pipe (3) to the turbocharger (1).
18. Install the 2 charge air cooler inlet air pipe bolts (4) and tighten to 25 N·m (18 lb ft) .

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19. Install the catalytic converter bracket bolts to the catalytic converter bracket (1) and tighten to 25 N·m (18 lb ft) .

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20. Install a NEW exhaust front pipe gasket (1).
21. Install the exhaust front pipe (2) to the catalytic converter (4).
22. Install the 3 NEW exhaust front pipe nuts (3) and tighten to 25 N·m (18 lb ft) .

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23. Install the heated oxygen sensor wiring harness retainer (4) to the bracket.
24. Connect the heated oxygen sensor wiring harness plug (1).
25. Install the exhaust pressure sensor hose (2) to the exhaust pressure sensor pipe (3).

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Note:  Fill 0,4 ml (0.013 oz) clean engine oil in the opening of the turbocharger oil feed pipe.
26. Install NEW copper seal rings (7, 9).
27. Install the turbocharger oil feed pipe hollow screw (1) and tighten to 21 N·m (15 lb ft) .
28. Install the radiator surge tank hose (2) to the coolant pipe (4).
29. Reposition the radiator surge tank hose clamp (3).
30. Install the vacuum hose (5) to the turbocharger wastegate actuator (6).

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31. Install the radiator outlet hose (3) to the coolant pipe (1).
32. Install the radiator outlet hose clamp (2).
33. Install the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
34. Close the hood.

Exhaust Heat Shield Replacement - Diesel and Petrol > < Exhaust Manifold Heat Shield Replacement - 1.7L Diesel LPL, LPV, LUD, LUE, LKR