Note: Exhaust system components can be replaced individually. If the pre-muffler or after-muffler of the standard exhaust system needs to be replaced, the connecting pipe must be sawn in the marked area, see also the following chapter. On a 1.4 liter diesel vehicle, the exhaust system consists of two branches, with the catalytic converter located where the pre-silencer is located on other engines.
Removing
Safety instructions: There is a risk of accident when lifting the vehicle! Read the section before starting work «Vehicle lifting».
Raise the car on the goats.
If available, remove lower engine cover.
Spray all bolts and nuts of the exhaust system with a rust converter. Leave the agent on the surfaces of the parts for some time to show its effect.
Petrol engine with direct injection: Disconnect plug connector for oxygen sensor 1.
Petrol engine: Disconnect connector from oxygen sensor 2.
Depending on the engine installed, unscrew the fastening of the front exhaust pipe from the bottom of the catalytic converter, exhaust manifold or turbocharger respectively.
Support the exhaust system or tie it with a wire to the body so that it does not fall down.
Attention: the flexible connector of the front exhaust pipe must not be bent more than 10°, otherwise it will be damaged.
Unscrew the fastening of the rear holders, lower the rear part of the exhaust system slightly, remove the subsequent muffler for a two-way exhaust system.
Unhook the pre-muffler from the suspension cushion and remove the exhaust system together with an assistant.
Parts of the exhaust system can also be replaced individually. If the connecting elements or bolts do not release, heat up the joint with a welding torch. Be sure to put an aluminum plate! Caution: Fire hazard!
Installation
Attention: Seals, nuts and bolts must be replaced. To make the nuts and bolts of the exhaust system easier to loosen later, it is recommended to lubricate them with a high-temperature paste, for example, Liqui Moly LM-508-ASC. Check suspension rubber pads for damage and replace if necessary.
If used parts of the exhaust system are reinstalled, their sealing surfaces must be cleaned with emery to remove deposits of carbon deposits and corrosion before joining.
Insert the front exhaust pipe into the suspension mounts, with a new seal, attach it to the catalytic converter, exhaust manifold or turbocharger respectively and screw lightly.
Slide the rear silencer with double clamp onto the front exhaust pipe and screw together with the suspension to the underbody.
Slide the downstream muffler with the repair double clamp onto the outlet pipe of the pre-muffler and screw together with the suspension to the underbody.
Tighten all bolts, but do not over tighten.
Align the exhaust system so that it rests on the hangers without tension. The distance of the exhaust system to any parts of the body must be at least 25 mm. If necessary, rotate or move the exhaust system longitudinally. Suspensions must be loaded evenly. Ensure that the pipes are pushed far enough into the clamps. There are embossings on the pipes at the joints for control.
Tighten bolts and nuts. The values of the tightening torques are given in the explanations to the figures.
Petrol engine: Connect the oxygen sensor connector 2.
Petrol engine with direct injection: Connect connector for oxygen sensor 1.
If available, install lower engine cover.
Lower the car.
Check the exhaust system for leaks, see relevant chapter below.
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