Exhaust System: Service and Repair

EXHAUST SYSTEM, REMOVING AND INSTALLING:

NOTES:

^ After working on the exhaust system, ensure that the system is not stressed, and has sufficient clearance from the bodywork. If necessary, loosen clamps and align muffler and front exhaust pipe so that sufficient clearance is maintained from the bodywork and the support rings are evenly loaded.

^ Replace self-locking nuts.

Part I:

Part I:
1 - Warm air collector plate
2 - Retainer
^ for warm air collector piate
3 - Hose
^ to air intake connection on Air Cleaner housing
4 - M6 - 10 Nm (7 ft lb)
M8 - 25 Nm (18 ft lb)
M10 - 40 Nm (30 ft lb)
5 - Mounting
^ Vehicles up to 09.91
6 - Gasket
^ Replace
7 - Oxygen sensor
^ 50 Nm (37 ft lb)
^ Only grease threads with "G5"; "G5" must not get into slots on sensor body
8 - Dimension -a- = 50 +/- 5 mm
9 - Three Way Catalyst
10 - Mounting
11 - Front exhaust pipe
^ from 08.95 = twin pipe
12 - 30 Nm (22 ft lb)
13 - Exhaust manifold
^ AAF engine:
2 piece with intermediate and corrugated pipes
14 - CO sampling pipe
^ up to 07.94
^ Additionally secured to intake manifold
15 - 15 Nm (11 ft lb)
16 - Plug
^Ensure it is tight and leak free

Part II:

Part II:
1 - Mounting
2 - M6 - 10 Nm (7 ft lb)
M8 - 25 Nm (18ft lb)
M10 - 4O Nm (3O ft lb)
3 - Dimension -b- = 25 to 35 mm
4 - Dimension -a- = 45 to 55 mm
5 - Rear muffler
6 - Clamp
^ Align exhaust system longitudinally at the clamps, so that the dimensions (items -3- and -4-) are maintained
7 - Center muffler
8 - Retaining ring
^ Note version