Exhaust System: Service and Repair

Exhaust system components, removing and installing

Note:
^ Removing and installing exhaust manifold, Refer to Turbo Charger, Service and Repair,Turbocharger System Components, Removing and Installing
^ After working on the exhaust system make sure that the system is not under stress, and that it has sufficient clearance from the bodywork. If necessary, loosen double and single clamps and align muffler and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
^ Replace self-locking nuts.





Front exhaust pipe and catalyst with attachments
1. from turbocharger
2. Gasket
^ Replace
3. 25 Nm (18 ft. lbs.)
4. Catalyst
5. to central muffler
6. Mounting
7. 25 Nm (18 ft. lbs.)





Muffler with mountings
1. 40 Nm (30 ft. lbs.)
2. from catalyst
3. Double clamp
^ Note installation position refer to Fig. 1
4. 25 Nm (18 ft. lbs.)
5. Mounting
^ Note installation position
6. Mounting
^ With retaining ring
7. Bracket
8. Mounting
9. Rear muffler
^ Align rear muffler stress free
10. Separating point
^ For repairs
^ Marked by three impressions on circumference of exhaust pipe
^ In production, exhaust pipe and rear mufflers are installed as a single component. For repairs, the exhaust pipe and rear muffler are supplied individually with a double clamp to allow connecting together.
^ Cut through connecting pipe at right angle to separation point
11. 20 Nm (15 ft. lbs.)
12. Tunnel bridge





Fig. 1 Double clamp installed position, checking
- Position double clamp approximately 5 mm from mark A (arrow -1-).

Note: Mark -A- is valid for vehicles with either manual or automatic transmissions.





Fig. 2 Installation position of mounting
Angled side on foot of mounting (arrow) points forward.





Fig. 3 Exhaust pipe, separation point
- Cut exhaust pipe at right angles to separating point (arrow -2-).
- Position repair clamp -4- when installing (arrows -1- and -3-)
^ Tightening torque 40 Nm (30 ft. lbs.)





Fig. 4 Rear muffler, aligning free of stress

Note: Mounting pins on exhaust pipe must run parallel with tunnel bridge (dimension -x- on left and right = the same).