Exhaust System

EXHAUST SYSTEM

RENEW

Fig 1:

Drive the car on to a ramp. Open the bonnet. Release the LH air cleaner toggle clips (1 Fig 1), remove the cover and remove the element (2 Fig 1). Disconnect the air temperature sensor feed wires. Release the RH air cleaner toggle clips, remove the cover and remove the element.

Raise the ramp.

Fig 2:

Slacken off the RH exhaust trim pipe securing screw (1 Fig 2). Remove the trim pipe (2 Fig 2).

Fig 3:

Slacken off the RH tail pipe/silencer to rear intermediate pipe clamp nut/bolt (1 Fig 3).

Displace the clamp from the union. Displace and remove the tail pipe/silencer assembly from the rear intermediate pipe.

Repeat the procedure for the LH tail pipe/silencer assembly.

Fig 4:

Slacken off the clamp (1 Fig 4) securing the RH rear intermediate pipe to the RH silencer. Remove the pipe (2 Fig 4).

Slacken off the clamp securing the LH rear intermediate pipe to the LH silencer. Remove the pipe. Remove the pipe mounting bar locknuts, and remove the mountings/collars.

Fig 5:

Remove the RH intermediate pipe clamp securing nut/bolt (1 Fig 5). Remove the RH intermediate pipe/silencer assembly (2 Fig 5). Remove the sealing olive.

Remove the LH intermediate pipe clamp securing nuts/bolts. Remove the LH intermediate pipe/silencer assembly. Remove the sealing olive.

Fig 6:

Remove the LH steering rack gaiter heat shield (Fig 6).

Remove the LH front pipe heat shield securing nuts, displace the heat shield for access.

Fig 7:

Remove the LH front pipe to manifold securing nuts (1 Fig 7).

Carefully disconnect the LH front pipe from the manifold.

Remove the RH steering rack gaiter heat shield. Remove the RH front pipe to manifold securing nuts. Carefully disconnect the RH front pipe from the manifold.

Align the steering lower U/J to ease front pipe removal.

Slacken off and displace the intermediate pipe/silencer clamps.

Remove and discard the front pipe sealing rings. Clean the sealing ring faces, clamps and olives. Fit new sealing rings to the LH front pipe. Locate the front pipe assembly into position. Fit the front pipe to the manifold. Fit but do not fully tighten the securing nuts.

Refit the heat shield. Fit but do not fully tighten the heat shield securing nuts.

Final tighten the front pipe securing nuts. Final tighten the heat shield securing nuts. Refit the LH rack gaiter heat shield. Fit new sealing rings to the RH front pipe.

Locate the front pipe assembly into position.

Fit the front pipe to the manifold. Fit and tighten the securing nuts.

Refit the RH rack gaiter heat shield.

Smear the LH front pipe olive with sealant.

Fit the olive to the LH intermediate pipe. Fit and align the intermediate pipe to the front pipe.

Position the clamp over the joints, and partially tighten the clamp nut/bolt.

Smear the RH front pipe olive with sealant.

Fit the olive to the RH intermediate pipe. Fit and align the intermediate pipe to the front pipe.

Position the clamp over the joints, and partially tighten the clamp nut/bolt.

Smear the LH intermediate pipe olive with sealant. Fit the olive to the pipe.

Smear the LH silencer union with sealant. Fit the silencer to the intermediate pipe. Fit the union clamp over the joints, and partially tighten the clamp nut/bolt. Smear the RH intermediate pipe olive with sealant. Fit the olive to the pipe.

Smear the RH silencer union with sealant. Fit the silencer to the intermediate pipe. Fit the union clamp over the joints, and partially tighten the clamp nut/bolt. Fit a new mounting/collar assembly to the LH rear intermediate pipe. Fit the pipe to the vehicle. Smear the LH silencer and rear intermediate pipe with sealant.

Engage the silencer to the pipe. Fit the union clamp over the joints, and partially tighten the clamp nut/bolt. Fit a new mounting/collar assembly to the RH rear intermediate pipe. Fit the pipe to the vehicle. Smear the RH silencer and rear intermediate pipe with sealant.

Engage the silencer to the pipe. Fit the union clamp over the joints, and partially tighten the clamp nut/bolt. Smear the LH rear intermediate pipe and tail pipe/silencer unions with sealant.

Fit and seat the LH tail pipe/silencer to the LH rear intermediate pipe. Fit the union clamp over the joints, and partially tighten the clamp nut/bolt.

Smear the RH rear intermediate pipe and tail pipe/silencer unions with sealant.

Fit and seat the RH tail pipe/silencer to the RH rear intermediate pipe. Fit the union clamp over the joints, and partially tighten the clamp nut/bolt.

Fit the exhaust trim pipes.

Align the exhaust system, and final tighten all clamp nuts/bolts. Lower the ramp.

Refit the left and right hand air cleaners.

Reconnect the air temperature sensor feed wires.

Run the engine and check for leaks. Road test the vehicle and check that the exhaust does not foul the underbody, chassis, etc. Re-align as necessary.

DATA

TORQUE FIGURES

Exhaust clamp nuts/bolts 15-18Nm
Exhaust mounting locknut 19-25Nm
Front pipe to manifold 30-35Nm
Tailpipe mounting to body 19-25Nm
Trim pipe screw 8-9Nm

SPANNER SIZES

7/16AF
1/2AF
9/16"AF
6mm Allen key

OILS/LUBRICANTS/SEALANTS

Exhaust sealer TIVOLI KAY ADHESIVES No 5696