Attention: When installing the exhaust system parts, make sure that the parts fit snugly into each other. Otherwise, incorrect data on the concentration of toxic substances will be obtained.
After removing the self-locking nut, the gaskets must be replaced. Mounting rings and rubber hangers should be checked for integrity and damage and replaced if necessary.
When installing a new exhaust system, it is recommended to replace all fasteners as well.
Withdrawal
Raise and support the car, remove the lower engine cover.
Apply a rust-dissolving penetrating compound to all threaded connections and wait for the compound to take effect. Unscrew the nuts from the end muffler holder.
Support the exhaust system with a floor jack and a suitable support, such as wood. The weight of the system is from 35 to 45 kg.
Remove the bolts and disconnect the front exhaust pipe from the exhaust manifold (gasoline engines) or from a turbocharger.
Unscrew the bolts and disconnect the exhaust system from the support on the gearbox.
Unhook the exhaust system from the rubber mounts (hangers) and take it off.
Attention: The catalyst is sensitive to impacts, so it must not be knocked or dropped.
Installation
Before installing the exhaust system, check whether the flange mating with the exhaust manifold is deformed and, if necessary, align the flange.
Attention: In order to make it easier to unscrew the nuts and bolts of the exhaust system during subsequent unscrewing, it is recommended to lubricate them with a high-temperature grease based on meoi.
Install the exhaust system and secure it with holders. Do not tighten bolts and nuts yet.
Align the exhaust system so that there is a distance of at least 25 mm from all its parts to the body. In addition, the end exhaust pipe must be positioned evenly in the recess of the body at the rear.
Diesel engine: Install the front exhaust pipe to the turbocharger and secure it with bolts/nuts. Check the O-ring first, replace it if necessary. Lubricate the O-ring with high temperature copper based grease.
Gasoline engines: Install the front exhaust pipe to the intake manifold with a new gasket and tighten the new self-locking nuts evenly. Tighten the bolts to 30 Nm. Then, on the second pass, tighten the bolts to 50 Nm.
Tighten all bolts and nuts. At the same time, tighten the fastening parts of the exhaust system on the gearbox last so that they sit without tension.
Tightening torques
- Exhaust pipe mountings on the exhaust manifold - 50 Nm.
- Threaded connections on triangular flange - 20 Nm.
Mounting the exhaust system on the gearbox:
- parts with M6 thread - 10 Nm;
- parts with M8 thread - 20 Nm;
- fastening earrings - 20 Nm;
- terminal muffler clamps - no more than 15 Nm.
Install the cross member, tighten the bolts to 20 Nm.
Start the engine and check the exhaust system for tightness by plugging the exhaust pipe with a rag. At the same time, the assistant should check all connections for exhaust gas leaks (hissing sound or ejections felt by the hand).
Install the bottom mudguard (casing) engine.