Removal and Installation

Exhaust system
Remove, reinstall except vehicles in KAT version. Service and Repair

Spark plug connector
Remove, refit.

Exhaust Manifold Left (The following steps apply if removing/installing left manifold)
Mounting clamp (2) on transverse pipe (1)
Unscrew, screw on.

Shield (3)
Remove, reinstall.

Exhaust gas recirculation line (68)
Disconnect from exhaust gas recirculation valve (60), reconnect.

Exhaust manifold (6)
Remove, reinstall. Unscrew screws (7) and nuts (9). Install with new nuts (9) and gaskets (5). Gaskets with metal side facing the cylinder head (see note below).

Exhaust Manifold Right (The following steps apply if removing/installing right manifold)
Exhaust system (only vehicles in KAT version)
Remove, reinstall. Service and Repair

Mounting clamp (2) for transverse pipe (1)
Unscrew, screw on.

Air cleaner
Remove, reinstall.

Shield (3)
Remove, reinstall.

Exhaust nuts (9) and bolts (7)
Remove, reinstall.

Exhaust manifold (4)
Remove from below. Mount with new nuts (9) and gaskets (5).
Gaskets with metal side facing cylinder head (see note below). Before tightening the nuts and bolts, flange on transverse pipe.

Exhaust system
Check for leaks by running engine.





A Engine 116
B Engine 117

NOTE: Install gaskets with the metal side facing the cylinder head. Observe difference between engines 116 and 117.





As of uprated output 09/87, the exhaust manifolds in KAT version are of the two-flute type without transverse pipe. Application and ID





A Previous version
B Present version

NOTE: Clips for expansion body between the exhaust manifolds modified in shape (easier removal/installation).





Production breakpoint: 06/90