Note: Vehicles with BLY and BVZ engines comply with the EU 2 exhaust emission standard. Some components of the exhaust system, such as the exhaust gas recirculation system, lambda probe 2 and lambda probe 2 after the catalytic converter, are not installed on these vehicles. This must be taken into account during installation work.
Note: The exhaust manifold is removed upwards.
Removal
Remove the noise insulation screen.
Fig. 2.88. Exhaust system holder
Unscrew the exhaust system holder (Fig. 2.88).
Note: On cars with engine letter designations BLX, BVX, the exhaust system bracket is removed together with the lambda probe cable box behind the catalytic converter.
Fig. 2.90. Fastening the inlet pipe
Unscrew the nuts securing the inlet pipe to the exhaust manifold (Fig. 2.90).
Note: The detachable elements in the intake pipe must not be bent more than 10°. There is a risk of damage.
Fig. 2.237. Exhaust manifold support bolts
Remove bolts 1..3 of the exhaust manifold supports (fig. 2.237).
Remove the engine cover, if present.
Fig. 2.238. Plug connections 1 and 2 of lambda probes
Remove the plug connections 1 and 2 of the lambda probes from the holder and disconnect them (fig. 2.238).
Note: On the engine with the letter designation BVY there is only one connector.
Fig. 2.239. Plug and water hose
Unlock water hose 1 and disconnect plug 2 (fig. 2.239).
BLR, BLX and BVX engines
Remove the wire box.
Continuation of installation operations for all vehicles
Fig. 2.240. Connecting pipe
Unscrew bolts 1..3 and remove the connecting pipe (fig. 2.240).
Remove the mounting bolt.
Unscrew the bolts on the intake manifold and remove the connecting pipe.
Release the lambda probe wiring harness 1.
Fig. 2.241. Location of the lambda probe
Remove the lambda probes 1 (fig. 2.241).
Note: Leave the water hoses from the EGR valve connected.
Fig. 2.242. Fastening the recirculation valve
Remove the EGR valve and set it aside (fig. 2.242).
Fig. 2.243. Fastening the protective screen
Remove the protective screen above the exhaust manifold by unscrewing bolts 1 and removing the protective screen (fig. 2.243).
Fig. 2.244. Fastening the exhaust manifold
Remove the exhaust manifold and pull it upwards (fig. 2.244).
Installing the exhaust manifold
Installation is carried out in the reverse order, taking into account the following.
All cable ties should be installed in their original locations.
Replace gaskets and self-locking nuts.
Lubricate the cylinder head and exhaust manifold dowel pins with heat-resistant paste.
Lubricate the threads of the lambda probes with heat-resistant paste; the paste should not get on the splines of the probe body.
Tightening torques
Exhaust manifold to cylinder head: 25 Nm
Protective screen to the exhaust manifold: 10 Nm.
Lambda probe: 55 Nm.
Bracket to subframe: 25 Nm.
Downpipe to exhaust manifold: 25 Nm.
EGR connecting pipe to EGR valve: 10 Nm.
EGR connecting pipe to exhaust manifold: 15 Nm.
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