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PRE-RELEASE

Intermediate exhaust pipe, front, B284

Intermediate exhaust pipe, front, B284

To remove

Warning

The turbocharger, exhaust manifold and centre exhaust pipe can be extremely hot. Take great care.


Important

Always use wing covers when working in the engine bay.



1. Remove the battery cover and the engine cover.

2. Remove the battery cable.

3. Remove the battery.

4. Remove Battery cover, bottom, B284 .

5. Remove Upper radiator member, B284 .

6. Unplug the mass air flow sensor connector. Detach the secondary air pipe, the delivery hose from the turbocharger intake manifold and the crankcase ventilation pipes.


7. Detach the turbocharger intake manifold from the air cleaner casing cover and the turbocharger.

8. Remove the bypass valve and unplug the connector.


9. Remove the upper radiator mounting.


10. Unplug the radiator fan connectors and detach the wiring harness from the fan cowling.

11. Remove the bolts of the lower turbocharger delivery pipe and the fan cowling.

12. Press the radiator assembly forward and remove the fan cowling.

13. Detach the intake manifold of the secondary air injection pump from the pump.


14. Detach the discharge pipe of the secondary air injection pump from the pump.

15. Unplug the intake air sensor connector (688).


16. Remove the turbocharger delivery pipe.

17. Remove the screw holding the dipstick tube.


18. Remove the heat shield of the front exhaust manifold.

Note

Lubricate the studs and nuts with rust removal oil and carefully loosen.


19. Detach the intermediate exhaust pipe from the turbocharger and the front exhaust manifold.



To fit


1. Attach the intermediate exhaust pipe to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with 90 513 210 Universal paste. Fit all nuts.

Important

The conical side of the nut should face the centre exhaust pipe.


2. Tighten the nuts as illustrated - first on the exhaust manifold and then on the turbocharger.

Tightening order 2a, 2b, 2c and 2d alternatingly on the turbocharger.

Tightening torque 30 Nm (22 lbf ft)

Important

The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the centre exhaust pipe and/or exhaust manifold must be replaced.



3. Fit the heat shield of the front exhaust manifold.

Tightening torque 10 Nm (7 lbf ft)


4. Fit the screw holding the dipstick tube.

Tightening torque 10 Nm (7 lbf ft)

5. Fit the turbocharger delivery pipe.


6. Plug in the intake air sensor connector (688).

7. Attach the discharge pipe of the secondary air injection pump.


8. Attach the secondary air injection pump's intake manifold to the pump.

9. Press the radiator assembly forward and position the fan cowling.

10. Fit the bolts of the lower turbocharger delivery pipe and the fan cowling.


11. Plug in the radiator fan connectors and attach the wiring harness to the fan cowling.

12. Fit the upper radiator mounting.

13. Fit the bypass valve and plug in the connector.


14. Attach the turbocharger intake manifold to the turbocharger and the air cleaner casing cover.


15. Plug in the mass air flow sensor connector. Attach the secondary air pipe, the delivery hose to the turbocharger intake manifold and the crankcase ventilation pipes.

16. Fit Upper radiator member, B284 .

17. Fit Battery cover, bottom, B284 .

18. Fit the battery.

19. Fit the battery cable.

20. Fit the battery cover and the engine cover.

21. Remove the wing covers and restore car electrical functions, see After disconnecting the battery .

22. Start the engine and check for any exhaust leakage.


PRE-RELEASE