Pic. 3.55. clamps (earrings) exhaust systems
1 - clamping belt bolt; 2 - clamping belt; 3 - connecting sleeve; 4 - end of the shock absorber pipe; 5 - shock absorber pipe; 6 - shock absorber pipe ear; 7 - rubber earring; 8 - body ear.
2. In car models with 1.6 and 1.8 engines, the exhaust pipe is hinged to the exhaust manifold. The exhaust pipe cuff 5 is pressed against the exhaust manifold cuff with spring clips 4 (pic. 3.56).
Pic. 3.56. Exhaust system elements
1 - gasket; 2 - exhaust manifold, 3 - sealing ring; 4 - spring clip; 5 - cuff of the exhaust pipe; 6 - exhaust pipe; 7 - connecting sleeve; 8 - shock absorber; 9 - clamping belt; 10 - clamping belt bolt; 11 - clamping belt bolt; 12 - rubber earring; 13 - shock absorber pipe ear; 14 - rubber earring; 15 - rubber earring; 16 - silencer; 17 - clamping belt; 18 - silencer; 19 - rubber earring.
To remove these clamps, the manufacturer provides a special tool, with which the clamp is unbent to the length necessary for removal. As much as it is inconvenient to remove the clamp without this tool, it is possible that installation will cause serious difficulties. Below are two ways to install the clamps.
Method 1
The clamp is stretched by alternately driving in several wedges that increase in height. The wedges must be made of 4 mm thick sheet with a not very large slope so that after driving in the wedge does not move back. Therefore, the stretching of the clamp must be performed in several stages:
A) Place the clamp horizontally on the vise along the slightly parted jaws.
b) Drive the first wedge.
V) Turn the clamp and drive in the next wedge, which is 4 mm larger than the previous one. The previous wedge falls out and a place is formed for driving in the next wedge. And so act until the moment when the clamp is not sufficiently expanded for the day of installation.
Attention: Do not stretch the clamp beyond measure, as it will lose its springy qualities.
G) The same must be done with the second clamp.
d) After laying the zipper on the cuff, it is necessary to knock out the wedges.
Method 2
This method consists in tying steel wire to one side of the clamp. The clamp has two holes, one at each end.
A) Through the window from the holes it is necessary to stretch a soft steel wire and tie its ends. You should get a loop 0.75 mm long.
b) Put the free end of the clip on the exhaust manifold collar, and lower the wire down under the car.
V) The assistant should press the cuff of the exhaust pipe into the manifold socket.
G) Place a wooden beam or board across the car body.
d) Insert the steel tube into the wire loop and, like a lever, pull the wire down, resting the tube on the wooden beam pressed against the body. The assistant at this time should push the clamp on the cuff of the exhaust pipe. If the loop made at the beginning is very long, it is enough to twist the wire to shorten it.
4. Before doing any work on the exhaust system, it is necessary to wait until the system has cooled down, and then coat the fixing bolts and connections with a thin layer of rust remover.
5. When installing the exhaust system, new bolts and nuts must be installed. It may turn out that it will be easier to cut the old bolts with a hacksaw than to unscrew them.
6. When removing any part of the exhaust system on models with 1.1 and 1.3L engines, it is usually easier to unscrew the bolts connecting the exhaust manifold and the front exhaust pipe and remove the entire system from the car, then separate it into separate parts or cut out the faulty parts with using a metal hacksaw.
7. Assemble the system in sections, starting from the front.
8. Before installing the system, it is necessary to lubricate all its connections with an exhaust system sealant. This will allow free movement of the parts relative to each other during mutual installation and ensure the tightness of the connections. Leave all bolts loose.
9. Start the engine and wait until the exhaust system reaches normal operating temperature. Then, with the engine idling, tighten all the mounting bolts and clamps, starting from the exhaust manifold and moving towards the rear shock absorber. Avoid touching any part of the system with bare hands as you may burn yourself. Perform work with gloves.
10. When tightening bolts and clamps, care must be taken that no part of the exhaust system is energized.
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