Replace catalytic converter/muffler

Unbolt the retaining clamp behind the catalytic converter (arrow).

Unhook the rear exhaust pipe from the rubber mounts and pull it off the catalytic converter. The illustration shows the rear rubber mount (arrow); the two front mounts are shown in illustration T-2641, see page 121.

If the rear exhaust pipe cannot be pulled off, heat the connection with a welding torch, if available. Shield the fuel tank with an asbestos sheet. Pull off the rear muffler using twisting movements.

If no welding equipment is available, cut through the exhaust pipe with a hacksaw or angle grinder. Saw the remaining piece on the intermediate pipe lengthwise and break it off with a chisel.

Loosen the bolts on the bolted flange and remove the catalytic converter.

To make the exhaust nuts and bolts easier to loosen later, coat them with a high-temperature copper paste, such as Liqui Moly LM-508-ASC.

Transfer the heat shield from the old exhaust pipe to the new one. Install the nuts and tighten to 10 N·m.

Before installation, clean the connecting flanges with a wire brush.

Install the catalytic converter with a new gasket on the front exhaust pipe. Tighten the 3 bolts to 25 N·m.

Install the rear exhaust pipe and hook it into the rubber mounts. Move the sections against each other to align them with the underbody. Make sure the rubber mounts are loaded evenly and not deformed. Caution: the exhaust system must have a clearance of at least 25 mm to all vehicle components.

Tighten the clamp bolt of the rear exhaust pipe clamp to 25 N·m.