Withdrawal
Raise the car.
Coat all bolted connections with rust remover. Wait some time for the action of the solvent.
Remove lambda probe.
Unscrew the front pipe from the bottom of the exhaust manifold (on a diesel engine: from a turbocharger).
Support the exhaust system with a wooden prop.
Vehicles with six-cylinder engines and automatic transmission only: Unbolt transmission cross member. The gearbox does not fall, as it is fixed on the rear support.
Unbolt exhaust system from gearbox mounting.
Disconnect the rubber rings of the middle suspension. On a four-cylinder engine, the suspension is located on the rear axle beam.
Loosen left and right mounting brackets for end muffler.
Pull out the complete exhaust system.
Installation
Before installing the exhaust system, check whether the exhaust manifold flange is bent and straighten if necessary.
Coat the studs on the exhaust manifold with copper paste.
Petrol engines: Screw the front pipe to the exhaust manifold with a new gasket with new self-locking nuts.
Diesel engines: Check O-ring -arrow- and replace if necessary. Coat the O-ring with high temperature copper paste. Screw the front exhaust pipe to the turbocharger. Tighten the new self-locking nuts evenly until both springs are compressed by 27 + 1 mm. The springs should not be fully compressed.
Push the end silencer onto the catalytic converter, screw the flanges with new gaskets. Tighten the bolts slightly. If required, sand the parts before assembly. When assembling the pipes, make sure that the O-rings are in the correct position. Be sure to replace self-locking nuts.
Attention: It is recommended to cover all bolts with high temperature paste, for example, Liqui Moly ZM-508-ASC, then it will be easier to unscrew them later.
Insert the exhaust system and screw onto the holders without tightening the bolts.
Install lambda probe.
Screw the front pipes to the exhaust manifold. Tighten the tension springs to 30 Nm. After that, on the 2nd pass, tighten the bolts to a tightening torque of 50 Nm.
Before tightening, align the system so that a distance of at least 25 mm from the body is ensured everywhere. In addition, the final exhaust pipe must be located at the same distance from the cutout in the body at the rear of the vehicle.
Fasten the mounting brackets so that they are under the tension of the rubber hangers. To do this, with the bracket released, move the muffler slightly forward (approx. A= 15 mm) and in this position, tighten with a torque of 20 Nm.
Tighten all bolts and nuts. When doing this, tighten the muffler bracket on the gearbox last to ensure its free position. If necessary, loosen the bolts -1- and move the bracket to the sides accordingly (Drawing W 2627).
Tightening torques for threaded connections of the exhaust system: front pipe to exhaust manifold -50 Nm; threaded connections of a triangular flange - 20 nm; bracket on the gearbox and on the muffler: M6 bolts -10 nm, M8 bolts - 20 nm; holding brackets - 20 nm; end silencer bracket - max. 15 nm.
If removed, insert the cross member of the automatic transmission box, tighten the bolts to a torque of 20 Nm.
Start the engine and check the tightness of the exhaust system by covering the exhaust pipe with a rag.
Lower the car.