Exhaust manifold - removal and installation

Since many different engines are installed in Volkswagen Transporter T4 cars, you can find differences in the design of exhaust systems (with or without a catalyst) in fig. 315, 316, 317 provided that new exhaust system. On some engines, the manifolds are connected to the front exhaust pipe with spring-sheet clips. In others, bolts are used for this purpose. To dismantle the spring clips of the Volkswagen T4 exhaust manifold, special tools are required.


Rice.
315 Exhaust system - 4-cylinder gasoline engine 1 - heated air supply bracket, 2 - cap, 3 - bolts, Mb, 10Nm, M8, 25Nm, M10, 40Nm, 4 - tube for connecting a gas analyzer (models up to July 1994 d), 5 - union nut, 30 Nm, 6 - gasket, 7 - exhaust manifold, 8 - bracket, 9 - intake exhaust pipe, 10 - suspension support, 11 - clamp, 12 - support ring, 13 - resonator, 14 - mounting dimension, a=45...55 mm, 15 - mounting dimension, b=15...25 mm 16 - mounting dimension, c=25...35 mm, 17 - muffler, 18 - catalytic converter, 19 - lambda probe (oxygen sensor), 50 Nm, 20 - heated air supply shield


Rice.
316 Exhaust system - 4-cylinder diesel engine 1 - bracket, 2, 8, 16 - bolts, 25 Nm, 3 - exhaust pipe, 4 - gasket, 5 - front exhaust pipe, 6 - gasket, 7 - catalytic converter, 9 - suspension support, 10 - nut, 20Nm, 11 - suspension ring, 12 - resonator, 13 - muffler, 14 - mounting dimension, a=50±5 mm, -15 - mounting dimension, b=10mm min, 17 - clamp


Rice.
317 Exhaust system - 5-cylinder diesel engine. Parts shown for ACV engine 1 - exhaust pipe, 2 - gasket, 3 - bracket, 4 - front exhaust pipe, 5 - gasket, 6 - nut, 25 Nm, 7 - catalytic converter, 8 - suspension support, 9 - support ring, 10 - bracket, 11 - clamp, 12 - nut, 40 Nm, 13 - resonator, 14 - mounting dimension, b=10 mm min. 15 - mounting dimension, a = 50 ± 5 mm, 16 - muffler, 17 - bolt, 5 Nm, 18 - heat-insulating casing, 19 - suspension support, 20 - rubber insert


♦ Wait for the exhaust system to cool down. Release the spring clips of the exhaust manifold Conveyor T4 using short wedges in the directions shown by the arrows in fig. 318.


Rice. 318 Tool for installation and removal of spring clips for fastening the exhaust pipe


♦ Move the exhaust pipe to the side and remove the clamp together with the expansion wedge.
♦ Install in reverse order.
Make sure that the clips are properly seated in the recesses provided for them. ♦ When installing the exhaust pipe, remember to place the O-ring between the exhaust manifold and the pipe.
If it is damaged, replace it. Removing the exhaust manifold in the case of a bolted exhaust pipe is a very simple operation.
During installation, tighten the bolts to the recommended torque. Screw the halves of the connecting clips to each other with both tips of the pipes.
Tighten the M8 nuts to a torque of 25 Nm, and the M10 nuts to a torque of 40 Nm. After installation, start the engine and check the tightness of the system, as well as whether the individual elements are connected correctly. A few words must be said about cars with a catalyst.
The probe is installed in the front exhaust pipe.
At operating temperatures above 300 ºС, the probe sends electrical signals to the control device.
If the signal voltage is less than 450 mV, the mixture is rich, and if more than 450 mV, the mixture is lean. The catalyst is placed in the exhaust system in front of the muffler.

Note: The fuel tanks of vehicles with a catalytic converter can only be filled with lead-free gasoline. If the catalyst is hot, the vehicle must not be towed.

Removal and installation of elements of system of an output of exhaust gases

On fig.
319 provides a typical exhaust system. In vehicles with a catalytic converter, removal and installation should not cause any difficulties; follow the instructions below exactly. Disconnect the connection to the exhaust manifold as described above.
The O-ring located between the exhaust manifold and the exhaust pipe must be replaced if it is damaged or leaking.
The bolts securing the thermal covers (if any) must be tightened with a torque of 10 Nm.
It must be remembered that rubber suspension parts are used for different suspension locations and cannot be interchanged.
Before tightening the clamping bolts of the connecting sleeves, screw both pipe ends together.
Tighten the M8 nuts to a torque of 25 Nm, and the M10 nuts to a torque of 40 Nm. After installation, start the engine and check the tightness of the system, as well as whether the individual elements are connected correctly. A few words must be said about cars with a catalyst. The probe is installed in the front exhaust pipe.
At operating temperatures above 300º, the probe sends electrical signals to the control device.
If the signal voltage is less than 450 mV, the mixture is rich, and if more than 450 mV, the mixture is lean. The catalyst is placed in the exhaust system in front of the muffler.
Note: The fuel tanks of vehicles with a catalytic converter can only be filled with lead-free gasoline. If the catalyst is hot, the vehicle must not be towed.

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