Exhaust System: Service and Repair
WM 260119 Removing and installing exhaust system
Technical values
Preliminary work
1. Remove complete centre underbody panel. -> 519319 Removing and installing centre underbody panel 519319 Removing and Installing Cover for Centre Underbody
2. Remove rear underbody panel. -> 519419 Removing and installing cover for rear underbody 519419 Removing and Installing Cover for Rear Underbody
Information
Component overview
Exhaust system for naturally aspirated engines (tailpipe covers not shown)
Exhaust system for turbocharged engines (tailpipe covers not shown)
Removing exhaust system
CAUTION
Hot components
- Risk of burns
-> Let hot components cool down.
-> Wear personal protective gear.
CAUTION
Heavy components
- Risk of squashing
-> Wear personal protective gear.
-> Get someone to help if necessary.
1. Release both connecting clamps (clamping sleeves) between catalytic converters and exhaust system. Push clamps onto exhaust system from the side. => Clamping sleeves. Exhaust clamps must not be reused.
Clamping sleeves
2. Remove strutting on underbody -1-
Strutting
3. Secure exhaust system using a lifter under the vehicle -1-.
Transmission jack securing exhaust system
3.1. Position transmission lifter under exhaust system so that both pipes are supported together at end of cardan shaft tunnel. -1-
3.2. Guide tension strap around both pipes and fasten. Raise exhaust system slightly.
4. Remove connecting strut between rear mufflers. -3- or -3-
Exhaust system for naturally aspirated engines (tailpipe covers not shown)
Exhaust system for turbocharged engines (tailpipe covers not shown)
5. In the case of a flap exhaust system (with vacuum units), disconnect vacuum hoses for flap actuation from vacuum units.
6. Remove rear holders for both rear mufflers. Remove two fastening screws from each muffler for this purpose -1-.
Rear muffler holder
7. Remove reinforcement plate from cardan shaft tunnel. => Reinforcement
Reinforcement
8. Remove left and right centre holders -2-.
Centre holder
9. Remove exhaust system downwards by lowering the transmission lifter.
Illustration shown exhaust system secured on transmission holder (arrows on tensioning belt)
9.1. When removing exhaust system, carefully push rear mufflers together and guide them downwards and out from rear apron. Rear mufflers make slight contact with heat shields of rear apron during this operation.
Information
Exhaust system installation dimensions
Information
- The exhaust system can expand up to 30 mm to the rear during operation.
- If heat causes the exhaust system to expand during operation, it may touch against the luggage-compartment pan, rear axle or heat protection panels if it is not installed correctly and cause noise (tapping, rumbling, droning).
- During installation, the exhaust system must be positioned when cool with sufficient distance from neighbouring components.
- When installing the exhaust system when cool, it is best to push the exhaust system towards the catalytic converters before fastening the clamping sleeves.
- Secure all 8 screws in the rubber mounting, push the exhaust system towards the catalytic converters, set the dimensions as shown in the illustration, screw on the clamping sleeves.
Installation dimensions of exhaust system when cool
Installing exhaust system
Always check the installation dimensions (danger of noise, component collisions).
1. Push new exhaust clamps (clamping sleeves) onto exhaust pipes. Screw connection must point downwards.
2. If you have not already done so, position exhaust system on a transmission lifter and secure using a tensioning belt. => Secure exhaust system on transmission lifter
Secure exhaust system on transmission lifter
3. Position the exhaust system under the vehicle using a transmission lifter. Do not install too tightly.
3.1. When installing the exhaust system, carefully push rear silencers together and guide them through rear apron. Carefully raise transmission lifter while doing so. Get a second mechanic to help if necessary.
4. Fit and tighten fastening screws for exhaust system -2 und 4- or -2 und 4-. => Tightening torque: 23 Nm (17 ftlb.)
Exhaust system for naturally aspirated engines (tailpipe covers not shown)
Exhaust system for turbocharged engines (tailpipe covers not shown)
5. The screws on the exhaust clamps must be pointing downwards. Adjust to maximum inclination and ensure the assembly length is the same on both exhaust pipes. => Installation position of exhaust clamp => Adjustment value: 10° => Tightening torque: 23 Nm (17 ftlb.)
Installation position of exhaust clamp
6. In the case of a Sport flap exhaust system connect vacuum hoses to vacuum units for flap actuation.
Information
Refer to the relevant repair instructions for tightening torques regarding parts belonging to the relevant body, transmission, chassis, electrical component groups.
7. Install reinforcement plate on cardan shaft tunnel. => Reinforcement
Reinforcement
8. Install strutting on underbody -1-
Strutting
9. Install connecting strut between rear silencers. => Tightening torque: 23 Nm (17 ftlb)
Subsequent work
1. Install centre underbody panel. -> 519319 Removing and installing centre underbody panel 519319 Removing and Installing Cover for Centre Underbody
2. Install rear underbody panelling. -> 519419 Removing and installing rear underbody panel 519419 Removing and Installing Cover for Rear Underbody