Exhaust system components, removing and installing

Exhaust system components, removing and installing





Note:
^ Always replace seals, gaskets and self-locking nuts.
^ All cable ties which are opened or cut open on removal must be replaced in same position when installing.
^ Any heat insulation sleeves which are taken off when removing must be re-attached in same position when installing.
^ After working on exhaust system ensure that system is not under stress, and that it has sufficient clearance from bodywork. If necessary, loosen clamps and align mufflers and exhaust pipes so that sufficient clearance is maintained to bodywork at all points and mountings are evenly loaded.
^ Flexible pipe connection (de-coupling element) in front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

1 - Center muffler
2 - 25 Nm
3 - Mounting
^ Replace if damaged
4 - 50 Nm
^ Different versions possible
^ Always replace
5 - Turbocharger
^ Cylinder bank 1 (right)
6 - Gasket
7 - Oxygen sensor - 55 Nm
8 - 50 Nm
^ Different versions possible
^ Always replace
9 - Turbocharger
^ Cylinder bank 2 (left)
10 - Gasket
^ Always replace
11 - Oxygen sensor - 55 Nm
^ Before catalytic converter
^ Cylinder bank 2 (left)
^ Grease threads only with high-temperature lubricant G 052112 A3. Lubricant must not get into slots on probe body
12 - Oxygen sensor - 55 Nm
^ After catalytic converter
^ Cylinder bank 2 (left)
^ Grease threads only with high-temperature lubricant G 052112 A3. Lubricant must not get into slots on probe body
13 - Front exhaust pipe
^ Cylinder bank 2 (left)
^ With starter catalytic converter and main catalytic converter
^ With flexible connection (de-coupling element)
^ Do not bend flexible connection more than 10° - otherwise it can be damaged
^ Protect from damage by knocks and impact
^ Components of exhaust pipe mounting Figure 3,
14 - Front clamp
^ Position of bolts go to Figure 1
^ Align exhaust system so it is free of stress before tightening clamp.
15 - 40 Nm
16 - Oxygen sensor - 55 Nm
17 - Front exhaust pipe
^ Cylinder bank 1 (right)
^ With starter catalytic converter and main catalytic converter
^ With flexible connection (de-coupling element)
^ Do not bend flexible connection more than 10° - otherwise it can be damaged
^ Protect from damage by knocks and impact
^ Components of exhaust pipe mounting go to Figure 3,
18 - Rear muffler
^ On left side of vehicle
^ Rear muffler and center muffler are one unit as original equipment, but can be replaced separately for repair purposes
^ Refer to Cutting point
^ Refer to Aligning exhaust system
19 - 25 Nm
20 - Mounting
21 - 25 Nm
22 - Rear muffler
23 - Cross brace
24 - 40 Nm
25 - Rear clamp





Figure 1 Installation position of front clamps
- Install clamps in position shown.
^ Angle (x = 15°)
^ Angle (B = 15°)
^ Bolted connections face outward





Figure 2 Installation position of rear clamps
- Install clamps so that ends of bolts are not below bottom circumference of clamp.
^ Bolted connections face each other





Figure 3 Components of mounting for front exhaust pipe
1 - Bolt - 25 Nm
2 - Washer
3 - Spring
4 - Spacer sleeve
5 - Spacer sleeve
6 - Lug
7 - Buffer
8 - Washer
9 - Bolt - 25 Nm

Note:
^ Collar of spacer sleeve -item 4- must face toward front exhaust pipe.
^ Collar of spacer sleeve -item 5- must face toward transmission support.