Exhaust System: Service and Repair

Exhaust system components, removing and installing

Note:
^ Removing and installing exhaust manifold.
^ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient clearance from the bodywork. If necessary, loosen the double and single clamps and align the muffler and exhaust pipe so that sufficient clearance is maintained and the support rings are evenly loaded.
^ Replace self-locking nuts.

Front exhaust system components

1. From - turbocharger
2. Gasket
^ Always replace
3. 25 Nm (18 ft. lbs.)
4. Catalytic converter
5. To central muffler
6. Support
7. 25 Nm (18 ft. lbs.)

Muffler with mountings

1. 40 Nm (30 ft. lbs.)
2. From catalytic converter
3. Double clamp
^ Note installation position see Fig. 1
4. 25 Nm (18 ft. lbs.)
5. Mounting
^ Note installation position see Fig. 2
6. Mounting
^ With retaining ring
7. Bracket
8. Mounting
9. Rear muffler
^ Align rear muffler stress free see Fig. 4
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 welded unit. For repairs the exhaust pipe and rear muffler are supplied as separate parts with a double clamp at the joint,
^ Cut through connecting pipe at right angle at separation point see Fig. 3
11. 20 Nm (15 ft. lbs.)
12. Tunnel bridge

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

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