Exhaust System: Service and Repair
Exhaust system components, removing and installing
WARNING!
^ Do not re-use any fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to., nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this information-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.
Note:
^ Always replace gaskets and self-locking nuts.
^ After exhaust system repairs, make sure exhaust system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen double clamps and align muffler and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
^ The exhaust flexpipe must not be bent more than 10°, otherwise it may be damaged.
Front wheel drive vehicles
1 - Nut
^ 40 Nm (30 ft. lbs.)
2 - Double clamp
^ Before tightening, ensure exhaust system is free of stress
^ Installation position: bolt ends point toward left
^ Installation position of bolt ends
^ Tighten bolts evenly
3 - Nut
^ 40 Nm (30 ft. lbs.)
4 - Double clamp
^ Used when front or rear muffler is replaced separately
^ Before tightening, ensure exhaust system is free of stress 2624
^ Installation position: bolt ends point toward rear
^ Installation position of bolt ends
^ Tighten bolts evenly
5 - Bolt
^ 25 Nm (18 ft. lbs.)
6 - Mount
7 - Gasket
^ Always replace
8 - Nut
^ Always replace
^ 30 Nm (22 ft. lbs.)
9 - Gasket
^ Always replace
10 - Turbocharger
^ Removing and installing, Refer to Powertrain Management
11 - Three Way Catalytic Converter (TWC)
12 - Heated Oxygen Sensor (H02S)
^ 50 Nm (37 ft. lbs.)
^ Only grease threads with "G 052112 A3." Do NOT allow grease to get into slots on sensor body
CAUTION! Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
13 - Nut
^ Always replace
^ 25 Nm (18 ft. lbs.)
14 - Bolt
^ 25 Nm (18 ft. lbs.)
15 - Mount
16 - Front exhaust pipe
^ With flexpipe
^ Flexpipe must not be bent more than 10° otherwise it may be damaged
^ To remove, unbolt floor crossmember (20 Nm/15 ft. lbs.)
^ Align exhaust system free of stress
17 - Mount
18 - Bolt
^ 25 Nm (18 ft. lbs.)
19 - Rear muffler
^ Factory installed with front muffler as one unit. If repair is necessary, replace separately
^ Separating point
^ Align exhaust system free of stress
20 - Front muffler
^ Factory installed with rear muffler as one unit. If repair is necessary, replace separately
^ Separating point
^ Align exhaust system free of stress
21 - Support ring
22 - Bolt
^ 25 Nm (18 ft. lbs.)
All wheel drive vehicles
1 - Front muffler
^ Factory installed with rear muffler as one unit. If repair is necessary, replace separately
^ Separating point
^ Align exhaust system free of stress
2 - Gasket
^ Always replace
3 - Nut
^ Always replace
^ 30 Nm (22 ft. lbs.)
4 - Gasket
^ Always replace
5 - Turbocharger
^ Removing and installing, Refer to Powertrain Management
6 - Three Way Catalytic Converter (TWC)
7 - Heated Oxygen Sensor (H02S)
^ 50 Nm (37 ft. lbs.)
^ Only grease threads with "G 052112 A3. " Do NOT allow grease to get into slots on sensor body
^ Disconnect Heated Oxygen Sensor (H02S) harness connector
8 - Nut
^ Always replace
^ 25 Nm (18 ft. lbs.)
9 - Bolt
^ 25 Nm (18 ft. lbs.)
10 - Mount
11 - Front exhaust pipe
^ With flexpipe
Caution: Flexpipe must not be bent more than 10° otherwise it may be damaged.
^ To remove, unbolt floor crossmember (20 Nm/15 ft. lbs.)
^ Align exhaust system free of stress
12 - Double clamp
^ Before tightening, ensure exhaust system is free of stress
^ Installation position: bolt ends point toward left
^ Installation position of bolt ends
^ Tighten bolts evenly
13 - Nut
^ 40 Nm (30 ft. lbs.)
14 - Mount
15 - Bolt
^ 25 Nm (18 ft. lbs.)
16 - Rear muffler
^ Factory installed with front muffler as one unit. If repair is necessary, replace separately
^ Separating point
^ Align exhaust system free of stress
17 - Mount
18 - Bolt
^ 25 Nm (18 ft. lbs.)
19 - Bolt
^ 25 Nm (18 ft. lbs.)
20 - Mount
21 - Nut
^ 40 Nm (30 ft. lbs.)
22 - Double clamp
^ Used when front or rear muffler is replaced separately
^ Before tightening, ensure exhaust system is free of stress
^ Installation position: bolt ends point toward left
^ Installation position of bolt ends
^ Tighten bolts evenly
23 - Support ring
24 - Bolt
^ 25 Nm (18 ft. lbs.)
Fig. 1 Individual mounting components for vehicles with manual transmission
1 - Buffer
2 - Spacer sleeve
3 - Washer
4 - Strap, right
5 - Washer
6 - Bolt (25 Nm/18 ft. lbs.)
7 - Spacer sleeve
8 - Strap, left
9 - Compression spring
10 - Bolt (25 Nm/18 ft. lbs.)
11 - Self-locking nut (25 Nm/18 ft. lbs.)
Fig. 2 Individual mounting components for vehicles with automatic transmission
1 - Washer
2 - Buffer
3 - Strap
4 - Spacer sleeve
5 - Bolt (25 Nm/18 ft. lbs.)
6 - Bolt
7 - Washer
8 - Compression spring
9 - Spacer sleeve
10 - Self-locking nut (25 Nm/18 ft. lbs.)
Fig. 3 Double clamp installation position
^ Install double clamp so bolt ends do not project over lower edge of double clamp.