Exhaust System Removal and Installation

PROCEDURE

Before removing or disassembling the exhaust system, soak all bolts and connections with a penetrating fluid that dissolves corrosion, such as WD-40. Before performing any work on the exhaust system, allow it to cool to avoid burns. To check the exhaust system for leaks, proceed as follows. Start the engine. An assistant must briefly block the tailpipe with a rag, and at that moment inspect the system. If any component of the exhaust system needs to be replaced, it may be easier to remove the entire system from the vehicle and then disassemble it. PROCEDURE 1. Disconnect muffler inlet pipe 9 (see figure Exhaust System) from exhaust manifold 12. On engines with a displacement of 1.6 and 1.8 L, use a special tool to spread spring clips 10 and remove them. On engines with a displacement of 1.1 and 1.3 L, unscrew the two bolts and remove the half-round clamps. 2. On engines with a displacement of 1.1 and 1.3 L, unscrew the bracket securing muffler inlet pipe 9 to the transmission. 3. Remove rings 1 and 3 and remove the entire exhaust system from the vehicle. 4. If the exhaust pipes cannot be separated, heat the connections with a blowtorch.

5. Before installation, lubricate all connections with exhaust system sealant. 6. Preassemble pipe 9 with secondary mufflers 7 and 6, without fully tightening the clamp bolts. 7. Install muffler inlet pipe 9 on exhaust manifold 12, replacing sealing ring 11. On engines with a displacement of 1.6 and 1.8 L, use a special tool to install spring clips 10. If no tool is available, spread clips 10 by driving a metal wedge 4 mm thick into them. Spread clips 10 only enough to fit them over the flange of the inlet pipe and the flange of the exhaust manifold. If clips 10 are spread too far, they may break or fail to clamp the inlet pipe to the exhaust manifold. On engines with a displacement of 1.1 and 1.3 L, fit the half-round clamps over the flange of the inlet pipe and the flange of the exhaust manifold and install the clamping bolts without fully tightening them. 8. On engines with a displacement of 1.1 and 1.3 L, insert the bolt securing the muffler inlet pipe to the bracket on the transmission. Install the nut and tighten it lightly only. 9. Install ring 1 and hang secondary muffler 6 on it. 10. Hang main muffler 2 on rings 1 and 3. 11. Connect main muffler 2 to secondary muffler 6 with clamp 5. Do not fully tighten the fastener. 12. Rock the system from side to side so that all components of the exhaust system hang freely. Check that all components have sufficient clearance from chassis parts and the body floor, and that rings 1 and 3 are evenly loaded. 13. On engines with a displacement of 1.1 and 1.3 L, tighten the bolts securing muffler inlet pipe 9 to the exhaust manifold and to the transmission bracket to 25 N·m. 14. Pull secondary muffler 6 forward with force so that ring 1 is stretched 5 mm toward the front of the vehicle. 15. Tighten the clamp bolts to 25 N·m.