AWD
Exhaust System Components, Removing And Installing
NOTE:
- Always replace gaskets and self-locking nuts.
- After exhaust system repairs, make sure exhaust system is not under stress and is far enough from the body. If necessary, loosen clamps and align mufflers and exhaust pipes so that there is adequate distance to vehicle body, and weight is evenly distributed among the exhaust hangers.
- Flex joint in front exhaust pipe must not be bent more than 10 degree, otherwise it may be damaged.
Exhaust System For Vehicles With All Wheel Drive (AWD) - Component Overview
1 23 Nm
2 Suspended mount
- Replace if damaged
3 Center muffler
- Factory-installed with rear muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
4 27 Nm
- Always replace
5 Exhaust manifold
- for cylinder bank 1 (right)
6 Gasket
- Always replace
7 Heated Oxygen Sensor (HO2S) -G39- (before catalytic converter)
- Bank 1, sensor 1
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
8 Heated Oxygen Sensor (HO2S) 2 -G108- (before catalytic converter)
- Bank 2, sensor 1
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
9 Exhaust manifold
- Cylinder bank 2 (left)
10 Gasket
- Always replace
11 27 Nm
- Always replace
12 Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131-
- Bank 2, sensor 2
- Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC).
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body.
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
13 Front exhaust pipe with catalytic converter
- for cylinder bank 2 (left)
- with decoupling element
- Decoupling element must not be kinked more than 10 degree, otherwise it may be damaged
- Protect from hit- and impact stress
- Install exhaust system free of stress
- Individual mounting components for vehicles with manual transmission, See Fig. 4.
- Individual mounting components for vehicles with automatic transmission 01 V, See Fig. 6.
14 Front clamping sleeve
- Before tightening ensure exhaust system is tension-free
- Installation position, See Fig. 1
- Tighten bolts evenly
15 40 Nm
16 Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) Heater 1 -Z29-
- Bank 1, sensor 2
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
17 Front exhaust pipe with catalytic converter
- for cylinder bank 1 (right)
- with decoupling element
- Decoupling element must not be kinked more than 10 degree, otherwise it may be damaged
- Protect from hit- and impact stress
- Install exhaust system free of stress
- Individual mounting components for vehicles with manual transmission Fig.3
- Individual mounting components for vehicles with automatic transmission 01 V See Fig. 5
18 Rear muffler
- for left side of vehicle
- Factory-installed with center muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
19 Suspended mount
- Replace if damaged
20 23 Nm
21 Rear muffler
- for right side of vehicle
- Factory-installed with center muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
22 23 Nm
23 40 Nm
24 Rear clamping sleeve
- Used when center or rear muffler is replaced separately.
- Before tightening ensure exhaust system is tension-free
- Installed position Fig. 2
- Tighten bolts evenly
Fig. 1 Installed position of front clamping sleeves
- Install double clamps so that the bolt ends do not project over lower edge of double clamp.
- Threaded connections face each other
Fig. 2 Installed position of rear clamping sleeves
- Install double clamps so that the bolt ends do not project over lower edge of double clamp.
- Threaded connections point outward
Fig. 3 Individual left mounting components for vehicles with manual transmission
1 - Self-locking nut (25 Nm)
2 - Spacer sleeve
3 - Strap
4 - Buffer
5 - Spacer sleeve
6 - Bolt (25 Nm)
7 - Washer
8 - Compression spring
9 - Spacer sleeve
Fig. 4 Individual right mounting components for vehicles with manual transmission
1 - Spacer sleeve
2 - Strap
3 - Compression spring
4 - Washer
5 - Bolt (25 Nm)
6 - Spacer sleeve
7 - Buffer
8 - Spacer sleeve
9 - Self-locking nut (25 Nm)
Fig. 5 Individual left mounting components for vehicles with automatic transmission 01 V
1 - Bolt (25 Nm)
2 - Heat shield for selector lever cable
3 - Spacer sleeve
4 - Buffer
5 - Strap
6 - Spacer sleeve
7 - Bracket
8 - Self-locking nut (25 Nm)
9 - Compression spring
10 - Spacer sleeve
11 - Washer
Fig. 6 Individual right mounting components for vehicles with automatic transmission 01 V
1 - Washer
2 - Bolt (25 Nm)
3 - Spacer sleeve
4 - Buffer
5 - Strap
6 - Spacer sleeve
7 - Self-locking nut (25 Nm)
8 - Compression spring
9 - Spacer sleeve
Fig. 7 Individual left mounting components for vehicles with automatic transmission 01J
1 - Bolt (25 Nm)
2 - Washer
3 - Compression spring
4 - Spacer sleeve
5 - Self-locking nut (25 Nm)
6 - Bolt (25 Nm)
7 - Spacer sleeve
8 - Buffer
9 - Strap
10 - Spacer sleeve
Fig. 8 Individual right mounting components for vehicles with automatic transmission 01J
1 - Self-locking nut (25 Nm)
2 - Bolt (25 Nm)
3 - Spacer sleeve
4 - Buffer
5 - Strap
6 - Spacer sleeve
7 - Bolt (25 Nm)
8 - Washer
9 - Compression spring
10 - Spacer sleeve.