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PRE-RELEASE

Front exhaust manifold, V6

Front exhaust manifold, V6

To remove

Important

The oxygen sensor cable must not be of twisted type. Twisted cables exposed to vibration can break.

The oxygen sensor is sensitive to impacts and jolting and must be handled with care.



1. Position the car on a lift.

2. Remove the upper engine cover.


3. Remove the turbo bypass pipe and valve.

4. Unplug the connector for the temp/pressure sensor and detach the turbocharger delivery pipe from the throttle body. Leave the hose clip hanging.

5. Raise the car and undo the turbocharger delivery pipe connection to the charge air cooler.

6. Plug the charge air cooler outlet. Lower the car.

7. Remove the turbo delivery pipe.

8. Remove the exhaust manifold's heat shield.


9. Detach the hose connection from the front SAI valve by pressing together the clip and pulling it back. Undo the nut on the valve bracket.

10. Note the radio code if applicable. Remove the battery and vent hose.

11. Undo the bolt securing the front SAI pipe.


12. Remove the SAI pipe with valve from the exhaust manifold.

13. Detach the crankcase ventilation pipe between the turbo inlet pipe and the cylinder head and the hose from the oil trap.

14. Detach the turbo intake pipe. Bend the pipe aside.

15. Detach the turbo's outlet hose to the charge air cooler.

16. Unplug the fan motor connectors.


17. Remove the radiator fan.

18. Close off the inlet and return water hoses to the turbo. Use 30 07 739 Pinch-off pliers .


19. Remove the water pipes to the turbo.

20. Undo and remove the dipstick tube.

21. Remove the front pipe from the turbo.

22. Unplug the oxygen sensor connectors.


23. Raise the car.

24. Cut off the cable tie securing the oxygen sensor cables. Note how the cables are run and lower the cable.

25. Separate the pipe joint between the front and rear exhaust systems.

Note

To ease disassembly of the front exhaust system, attach a 83 95 212 Cable tie around the front pipe.


26. Detach the front pipe from the rear exhaust manifold. Lower away the front exhaust system.

27. Remove the turbo's oil return pipe.


28. Remove the turbo mounting bracket.

29. Detach the oil pipe from the oil filter adapter.

30. Lower the car to the floor.

31. Undo the nuts securing the front exhaust manifold.


32. Remove the front exhaust manifold with turbo.


To fit

Important

The oxygen sensor cable must not be of twisted type. Twisted cables exposed to vibration can break.

The oxygen sensor is sensitive to impacts and jolting and must be handled with care.


Note

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


Note

Spray the connector with Kontakt 61, part no. 30 04 520, before plugging it in.



1. Clean the sealing surfaces and fit a new gasket to the front exhaust manifold.

2. Fit the front exhaust manifold with turbo.

Tightening torque: 20 Nm (14.7 lbf ft).


Important

It is essential that there is oil in the turbo bearing housing when the engine is started.

Fill the turbo oil inlet with oil from an oilcan. Rotate the compressor by hand many times so that the oil penetrates into the bearings.


3. Raise the car.

4. Fit a new gasket on the front pipe against the rear exhaust manifold.

Note

To ease disassembly of the front exhaust system, attach a 83 95 212 Cable tie around the front pipe.


5. Fit the front exhaust pipe to the rear exhaust manifold.

Tightening torque: 40 Nm (29.5 lbf ft).


6. Fit the pipe joint between the front and rear exhaust systems.

Tightening torque: 22 Nm (16.2 lbf ft).

7. Secure the oxygen sensor cables with cable ties. Carefully run the cables back to the oxygen sensor connectors.

8. Fit the oil pipe to the oil filter adapter. Fit new gaskets and sealing washers.

Tightening torque: 20 Nm (14.7 lbf ft).


9. Fit the turbo mounting bracket.

Tightening torque: 24 Nm (17.7 lbf ft).

10. Fit the turbo's oil return pipe.

Tightening torque:

M6 bolt: 14 Nm (10.3 lbf ft)

11. Lower the car to the floor.

12. Plug in the oxygen sensor connector.


13. Bolt the front exhaust pipe to the turbo.

Tightening torque: 24 Nm (17.7 lbf ft).

14. Fit the dipstick tube.

15. Fit the turbo water return pipe. Use new seal washers.

Tightening torque:

Banjo bolt, turbo 25 Nm (18.4 lbf ft)

Retaining screw cylinder head 14 Nm (10.3 lbf ft)

16. Remove the pinch-off pliers from the inlet and return water hoses to the turbo.

17. Fit the radiator fan.

Tightening torque: 8 Nm (5.9 lbf ft)

18. Plug in the connectors to the radiator fan motors.


19. Fit the hose between the turbo and the charge air cooler.

Tightening torque: 8 Nm (5.9 lbf ft)


20. Fit the turbo's intake pipe.

Tightening torque:

V-clamp 3 Nm (2.2 lbf ft)

U-clamp cylinder head 14 Nm (10.3 lbf ft)

21. Fit the hose to the mass air flow sensor

22. Fit the crankcase ventilation pipe between the cylinder head and the turbo inlet pipe. Connect the hose from the oil trap.

23. Fit the SAI pipe with valve and new gaskets to the bracket and the hose connection to the front SAI valve. Check the connection.

24. Lower the turbo delivery pipe and connect it to the throttle body.


25. Raise the car and remove the plug in the charge air cooler outlet.

26. Connect and tighten the turbocharger delivery pipe hose clip to the charge air cooler.

27. Lower the car and tighten the turbocharger delivery pipe hose clip to the throttle body.

28. Plug in the connector for the temp/pressure sensor.


29. Fit the front exhaust manifold's heat shield.

Tightening torque: 24 Nm (17.7 lbf ft).

30. Fit the turbo bypass pipe with valve.

Tightening torque: 8 Nm (5.9 lbf ft)

31. Fit the battery and vent hose. Fit the battery cover.

32. Check the oil and water levels. Top up as necessary.

33. Start the engine and check for any oil and water leakage.

34. Fit the upper engine cover.

35. Reset the clock and program the radio code if applicable.


PRE-RELEASE