Exhaust System Removal and Installation

Exhaust system. Engine without turbocharger. The 1.8 L engine with turbocharger has differences at the muffler inlet pipe flange. 1 - crossmember With hole for mounting the exhaust system. 2 - mount 3 - bolt, 25 N·m 4 - inlet pipe, catalytic converter Do not drop, protect from impacts and shocks. 5 - nut, 40 N·m Self-locking, a new one must always be installed. 6 - seal. Always replace. 7 - exhaust manifold 8 - nut, 25 N·m 9 - oxygen sensor, 50 N·m 10 - clamp Working position: bolted connection is located horizontally on the left side of the vehicle. 11 - nut, 40 N·m 12 - mount 13 - bolt, 25 N·m 14 - center and rear mufflers When repairing, they are separated and replaced individually. 15 - nut, 25 N·m

Exhaust system. Diesel engine 1 - bolt, 20 N·m 2 - tunnel bridge With hole for mounting the exhaust system. 3 - mount 4 - bolt, 25 N·m 5 - bolt, 25 N·m 6 - mount 7 - bolt, 25 N·m 8 - nut, 25 N·m Self-locking, must always be replaced. 9 - seal. Always replace. 10 - inlet pipe, catalytic converter Do not drop, protect from impacts and shocks. 11 - clamp Working position: bolted connection is located horizontally on the left side of the vehicle. 12 - nut, 40 N·m 13 - mount 14 - mount 15 - bolt, 25 N·m 16 - mount 17 - rear muffler

REMOVAL

CAUTION

Exhaust system components can be removed separately. The center and rear mufflers can be separated from each other. They are available as individual parts; refer to the subsection Replacing Center/Rear Muffler. When lifting and supporting the vehicle on stands, there is a risk of injury. Therefore, first read the subsection Jacking Up the Vehicle.

PROCEDURE

1. Raise the vehicle and support it on stands.

2. Spray all exhaust system bolts and nuts with rust penetrating fluid. Allow some time to soak.

3. Unscrew the oxygen sensor connector cover next to the catalytic converter (arrow at bottom of illustration). Disconnect the electrical wire with clips (upper arrow) at the heat shield. Remove the connector from the cover and disconnect it.

4. Unscrew the lower inlet pipe mounting bolts at the exhaust manifold or turbocharger.

5. Support the exhaust system with stands or suspend it with wire from the vehicle underbody so that it does not fall.

CAUTION

Under no circumstances allow the exhaust system to drop, as this may damage the ceramic substrate of the catalytic converter. Damage will require replacing the catalytic converter.

6. Unscrew the bolts on both sides securing the front exhaust system crossmember to the underbody.

7. With an assistant, remove the exhaust system from the mounts. INSTALLATION

CAUTION

Always replace seals, nuts and bolts with new ones. To facilitate later disassembly, it is recommended to coat the exhaust system nuts and bolts with high-temperature paste, such as Liqui Moly LM-508-ASC, before installation.

8. If the mufflers are not being replaced, clean the sealing and contact surfaces of rust and sealant residue with sandpaper before assembly.

CAUTION

Do not bend the flexible (decoupling) element in the turbocharger inlet pipe by more than 10 °, otherwise it may be damaged.

9. Secure the exhaust system brackets to the front crossmember with bolts so that the bent side of the bracket (arrow in illustration) faces the direction of travel.

10. With an assistant, install the exhaust system and suspend it from the rear in the rubber mounts.

11. Secure the front crossmember to the underbody with bolts, tightening to 25 N·m.

12. Engines without turbocharger: Secure the inlet pipe to the exhaust manifold with bolts using a new gasket, and tighten crosswise in the sequence shown in the illustration to 40 N·m.

13. Engines with turbocharger: Secure the inlet pipe with a new gasket to the turbocharger, tightening crosswise to 40 N·m for gasoline engines and 25 N·m for diesel engines.

14. Align the exhaust system so that it rests in the mounts without tension.

15. Tighten the bolts and nuts to the torques specified in the Specifications.

16. Install the engine compartment undercover; refer to the subsection Removal and Installation of Engine Compartment Undercover.

17. Route the oxygen sensor cable into the clips and connect it. Screw the connector cover onto the underbody.

18. Lower the vehicle to the wheels.

19. Check the exhaust system for leaks; refer to the corresponding subsection Checking Exhaust System Condition.