Exhaust System: Service and Repair

NOTE:
- Exhaust manifold, replacement: steps 1 through 3
- Exhaust pipe, replacement: steps 4 and 5

Exhaust Manifold, Replacement





1. Undo front exhaust pipe:
- Remove nuts in flanged joints with exhaust manifold.
- Remove carriage bolts.





2. Remove exhaust manifold:
- Remove two heat shields from exhaust manifold.
- Free exhaust manifold from pin bolts.
- Twist exhaust manifold 90° to the right and lift.
- Check gasket surface with cylinder head.

CAUTION:
- Applies to cars fitted with A/C
- Do not damage pressure switch on A/C-pipe.

NOTE: When installing pin screws, always use Loctite (strong), P/N 1161076-5.





3. Install exhaust manifold:
- Install exhaust manifold, use new gaskets.
- Align front exhaust pipe with exhaust manifold using carriage bolts.
- Tighten exhaust manifold to cylinder head. Tighten to 25 Nm (18.5 ft lb).
- Reinstall heat shields.
- Tighten front exhaust pipe to exhaust manifold, use thread sealing compound on carriage bolts.
Tighten nuts to end of thread.
Do not tighten more than 10 Nm (7.4 ft lb).

NOTE: Remember to reinstall springs and washers with two exhaust pipe nuts.

Exhaust pipe, Replacement

General:
- Check rubber mountings, replace if necessary.
- The distance between exhaust system and body should not be less than 20 mm.





4. Installation of complete system:
- Follow this procedure to avoid stresses in the system:
1st step: Insert silencer tail pipe between floor and rear axle.
2nd step: Support silencer in rubber mountings.
3rd step: Install three-way catalytic converter (TWC) and partly tighten flanged joint to exhaust manifold.
4th step: Connect the exhaust system to the TWC, lubricate connection with thread sealing compound (P/N 1 161 035-9).
Align other exhaust system components.
5th step: Tighten TWC to exhaust pipe.
Tighten nuts to end of thread, tighten to 10 Nm (7.4 ft lb).
6th step: Tighten front/rear pipe connections to 25 Nm (18 ft lb).





5. Carry out function test:
- Start engine.
- Check for leaks.