Vehicles With All Wheel Drive
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 has sufficient clearance 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 mounts.
- Decoupling element 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
Component Locations, Overview:
1 Center muffler
- Factory-installed with rear muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
2 23 Nm
3 Suspended mount
- Replace if damaged
4 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, See Fig. 4
- Individual mounting components for vehicles with automatic transmission 01V, See Fig. 6
5 27 Nm
- replace
6 Exhaust manifold
- for cylinder bank 1 (right)
7 Seal
- replace
8 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
9 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
10 Exhaust manifold
- Cylinder bank 2 (left)
11 Seal
- replace
12 27 Nm
- replace
13 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
14 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.3
- Individual mounting components for vehicles with automatic transmission 01V, See Fig.5
15 Front clamping sleeve
- Before tightening ensure exhaust system is tension-free
- Installation position, See Fig. 1
- Tighten bolts evenly
16 40 Nm
17 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
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 Transverse beam
20 Bolt
21 Suspended mount
- Replace if damaged
22 23 Nm
23 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
24 25 Nm
25 40 Nm
26 Rear clamping sleeve
- Used when center or rear muffler is replaced separately.
- Before tightening ensure exhaust system is tension-free
- Installed position, See Fig. 2
- Tighten bolts evenly
Fig. 1 Installed position of front clamping sleeves
- Install double clamps so that the bolt ends do not project beyond 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 beyond lower edge of double clamp.
- Threaded connections point toward the right
Fig. 3 Individual left mounting components for vehicles with manual transmission
1 Self-locking nut (25 Nm)
2 Washer
3 Spacer sleeve
4 Strap
5 Buffer
6 Washer
7 Bolt (25 Nm)
8 Spacer sleeve
9 Compression spring
10 Washer
11 Bolt (25 Nm)
Fig. 4 Individual right mounting components for vehicles with manual transmission
1 Bolt (25 Nm)
2 Washer
3 Buffer
4 Strap
5 Spacer sleeve
6 Washer
7 Self-locking nut (25 Nm)
8 Bolt (25 Nm)
9 Washer
10 Compression spring
11 Spacer sleeve
Fig. 5 Individual left mounting components for vehicles with automatic transmission 01V
1 Self-locking nut (25 Nm)
2 Bolt (25 Nm)
3 Heat shield for selector lever cable
4 Spacer sleeve
5 Buffer
6 Strap
7 Spacer sleeve
8 Bracket
9 Bolt (25 Nm)
10 Washer
11 Compression spring
12 Spacer sleeve
Fig. 6 Individual right mounting components for vehicles with automatic transmission 01V
1 Washer
2 Strap
3 Buffer
4 Spacer sleeve
5 Bolt (25 Nm)
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Self-locking nut (25 Nm)