Exhaust manifold

F4R or K4J or K4M

Essential special tools
Tool 1495-01	24 mm socket for removing / refitting oxygen sensors - 1/2" square drive and 24 mm external hex

Tightening torques
manifold nuts (K4J and K4M engines)	2.3 +/- 0.3 daN.m
manifold nuts (F4R engine)	1.8 daN.m
heat shield bolt	1 daN.m
oxygen sensors	4.5 daN.m
exhaust line mounting bracket bolts to body	2.1 daN.m
bracket bolt to exhaust manifold	0.8 daN.m
exhaust manifold bracket nut to gearbox	2.1 daN.m
exhaust flange nuts	2 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Disconnect the battery

K4J

• Remove the air filter housing (Fuel Metering chapter, Air Filter Housing, page 12A-14).

F4R or K4M

• Remove the intake manifold (Fuel Metering chapter, Intake Manifold, page 12A-26).

• Disconnect the downstream oxygen sensor (1).

• Remove the exhaust flange fasteners (2).
• Remove the bracket (3) from the exhaust manifold.

Note: Mark the position of the exhaust flexible mount brackets on the body with a marker.

• Remove the bolt (4) securing the exhaust line rubber mount bracket to the body.

• Remove the bolt (5) securing the silencer rubber mount bracket to the body.
• Move the exhaust line rearward.

• Remove the oxygen sensor (6) using tool (Mot. 1495-01).
• Remove the upper heat shield (7) from the exhaust manifold.

• Remove:

• the nine new exhaust manifold mounting nuts,
• the exhaust manifold.

ON WORKBENCH

• Remove the lower heat shield.

INSTALLATION

• Always replace:

• the manifold gaskets,
• the exhaust flange gaskets,
• the manifold nuts.

• Refit in the reverse order of removal.
• Tighten in the following order and to the following torques:

• manifold nuts (K4J and K4M engines) (2.3 +/- 0.3 daN.m),
• manifold nuts (F4R engine) (1.8 daN.m),
• the heat shield bolt (1 daN.m),
• the oxygen sensors (4.5 daN.m),
• the exhaust line rubber mount bracket bolts to body (2.1 daN.m),
• the bracket bolt to exhaust manifold (0.8 daN.m),
• the exhaust manifold bracket nut to gearbox (2.1 daN.m) (F4R engine only),
• the exhaust flange nuts (2 daN.m).

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).

K9K

Essential special tools
Mot. 1567	Remote pliers for EGR clamps

Tightening torques
exhaust manifold studs	0.9 daN.m
exhaust manifold mounting nuts	2.6 daN.m
EGR housing mounting bolts	2.1 daN.m
lifting ring	2.1 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Disconnect the battery.

• Remove:

• the turbocharger (see Turbocharging chapter),
• the metal EGR tube (1),
• the lifting ring (2),
• the metal air intake tube (3),
• the two EGR housing mounting bolts (4),
• the EGR housing,
• the eight manifold mounting nuts (5),
• the manifold.

INSTALLATION

• Replace the manifold gasket.
• Refit the manifold.
• Tighten the exhaust manifold studs to torque (0.9 daN.m).
• Tighten the exhaust manifold mounting nuts to torque in sequence (2.6 daN.m).
• Refit:

• the EGR housing,
• the new EGR housing tube,
• the two new clamps on the new housing tube.

• Tighten the new clamps using tool (Mot. 1567).
• Tighten the EGR housing mounting bolts to torque (2.1 daN.m).
• Tighten the lifting ring to torque (2.1 daN.m).
• Refit in the reverse order of removal.
• Refit the turbocharger (Turbocharging chapter, Turbocharger, page 12B-4).

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).