Contents: Removal ↳ Installation ↳
Attention! Production models use two-piece exhaust systems, which can be replaced with a three- or four-piece exhaust system in the event of repair. Production systems cannot replace the middle muffler separately, and the other two mufflers must also be replaced in the event of repair. If only the additional muffler needs to be replaced, the exhaust system must be cut.
Removal
Disconnect the negative (-) cable from the battery.
Warning! This will erase data in electronic memory devices, such as the engine fault memory device or radio code. Please read the section "Removing and installing the battery" carefully before disconnecting it.
Raise the car.
Spray all exhaust system mounting bolts and nuts with rust dissolving spray. Allow the spray to act on the rust for a while.
Disconnect the rear section of the exhaust system from the front section.
Petrol engines: Remove the oxygen sensor "1". To do this, disconnect the multi-pin plug - 2-; when disconnecting the plug, do not pull on the wire. Unscrew the oxygen sensor on the front exhaust pipe and remove it together with the seal. Do not touch the tip of the measuring probe or allow it to become dirty.
Unscrew the front exhaust pipe from the manifold, it is secured with two nuts "3". Remember the mounting position of the springs.
Check the rubber holders for cracks. To do this, press the exhaust pipe down slightly. Use a flashlight to illuminate the connecting hoses, check them and replace them if necessary.
Disconnect the exhaust pipes from all rubber retaining elements and remove them. Disconnect the additional muffler from the middle muffler, see the next section.
Installation
Replace the rubber holders if necessary.
Attention! The rubber holders in the catalytic converter area are made of a special heat-resistant material. Therefore, only the holders provided may be used here.
Before installation, clean the manifold, front exhaust pipe flange and connecting flange with a steel brush. Use only new bolts and nuts during installation. Apply a layer of high-temperature paste (such as Liqui Moly LM-508-ASC paste) to all bolts and nuts to make them easier to unscrew at a later stage.
Caution! High-temperature paste must not enter the exhaust system before the catalytic converter. Liquid sealant must not be used, as the catalytic converter will become contaminated during operation.
Install the front exhaust pipe with a new seal and bolt it to the manifold.
Attention! New spacer pins, springs and pins can be installed in advance, to release the compressed spring, do not pull the stud, loosen the compressed spring by gradually releasing the nut. Install new spacer pins on the exhaust manifold and secure them with pins.
Install the rear exhaust pipe with a new seal and secure it with bolts.
Install the exhaust system in rubber holders. Match the individual parts of the system to each other and orient it relative to the bottom of the car. Make sure that the rubber elements experience the same load and do not deform.
Attention! The distance between the exhaust system and all vehicle parts must be at least 25 mm.
Tighten the fasteners connecting the rear and front exhaust pipes to a torque of 40 Nm.
Screw on the new self-locking nuts securing the front exhaust pipe to the manifold, screw them on until the nuts touch the flange of the expansion pins, then tighten them to a torque of 40 Nm.
Carefully install the oxygen sensor with a new seal, tighten it to 60 Nm. Connect the connector.
Lower the car onto its wheels.
Connect the ground wire to the battery. Set the existing clock and set the radio anti-theft code.
Start the engine and check the exhaust system for leaks. To do this, cover the end of the pipe with a rag. If the engine stalls, the exhaust system is leaky.
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