Vehicles With Front 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 Front Wheel Drive (FWD) - Component Overview
Component Locations, Overview:
1 23 Nm
2 Suspended mount
- Replace if damaged
3 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 01J, See Fig. 6
4 27 Nm
- replace
5 Exhaust manifold
- for cylinder bank 1 (right)
6 Seal
- 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
- for cylinder bank 2 (left)
10 Seal
- replace
11 27 Nm
- 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.3
- Individual mounting components for vehicles with automatic transmission 01J, See Fig. 5
14 Front clamping sleeve
- Before tightening ensure exhaust system is tension-free
- Installed 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 Suspended mount
- Replace if damaged
18 23 Nm
19 Rear muffler
- with exhaust flap
- Factory-installed with center muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
20 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
21 40 Nm
22 Center muffler
- Factory-installed with rear muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
23 Suspended mount
- Replace if damaged
24 23 Nm
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 sleeve
- Alpha = 30 degree
- Bolt heads (arrow) face toward fuel tank -1-
Fig. 3 Individual left mounting components for vehicles with manual transmission
1 Bolt (25 Nm)
2 Spacer sleeve
3 Strap
4 Buffer
5 Washer
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Self-locking nut (25 Nm)
Fig. 4 Individual right mounting components for vehicles with manual transmission
1 Self-locking nut (25 Nm)
2 Washer
3 Washer
4 Buffer
5 Spacer sleeve
6 Washer
7 Washer
8 Bolt (25 Nm)
9 Spacer sleeve
10 Strap
11 Strap
12 Compression spring
13 Washer
14 Bolt (25 Nm)
Fig. 5 Individual left mounting components for vehicles with automatic transmission 01J
1 Self-locking nut (25 Nm)
2 Washer
3 Bracket
4 Strap
5 Buffer
6 Spacer sleeve
7 Bolt (25 Nm)
8 Bolt (25 Nm)
9 Washer
10 Compression spring
11 Bolt (25 Nm)
12 Spacer sleeve
13 Self-locking nut (25 Nm)
Fig. 6 Individual right mounting components for vehicles with automatic transmission 01J
1 Spacer sleeve
2 Strap
3 Buffer
4 Spacer sleeve
5 Bolt (25 Nm)
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Washer
11 Self-locking nut (25 Nm)