Exhaust Rear Auxiliary Muffler Replacement

Exhaust Rear Auxiliary Muffler Replacement

Removal Procedure

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Caution:
Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage the exhaust flex decoupler.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Remove the underbody rear air guide. Refer to Underbody Rear Air Deflector Replacement Service and Repair.





3. Remove the 2 exhaust rear muffler hanger insulators (3) from the exhaust rear muffler.

4. Remove the exhaust rear auxiliary muffler hanger insulators bracket bolt (1) from the exhaust rear auxiliary muffler bracket (2).

5. Remove the exhaust rear muffler hanger insulators bracket (2) from the exhaust rear muffler end pipe bracket (2).

6. Place the exhaust system onto the rear axle.





7. Note the dent marks (1) around the exhaust pipe.





Note:
A second technician is required.

8. Cut the exhaust rear auxiliary muffler from the exhaust rear muffler with a suitable tool at the marked position (2).

9. Remove the exhaust rear auxiliary muffler.

10. Remove the exhaust rear auxiliary muffler bracket from the exhaust rear auxiliary muffler.

Installation Procedure

1. In case of reuse of the exhaust parts, check the exhaust pipes at the separating sets for the following conditions:

* roundness of the exhaust pipe, any deformation in the range of the double-clamp must be eliminated

* burrs inside and outside the exhaust pipe at the cutting edge, use a file to eliminate

* rust at the exhaust pipe outside, use a sandpaper to eliminate





Note:
A second technician is required.

2. Lift the exhaust rear muffler from the rear axle and position in mounting position.

3. Install the 2 exhaust rear muffler hanger insulators (5) to the exhaust rear muffler (6) and the exhaust rear muffler brackets at the underbody.

4. Preinstall the exhaust pipe clamp (1) to the exhaust rear auxiliary muffler (4).

5. Install the exhaust rear auxiliary muffler bracket (2) to the exhaust rear auxiliary muffler (4).

6. Install the exhaust rear auxiliary muffler (4) to the exhaust rear muffler (6).

Caution:
Refer to Fastener Caution Fastener Caution.

7. Install the exhaust rear auxiliary muffler bracket bolt (3) to the exhaust rear auxiliary muffler bracket (2) and tighten to 25 Nm (18 lb ft).

8. Install the exhaust pipe clamp (1) and loosely tighten.

9. Position the exhaust rear auxiliary muffler (4).

10. Tighten the exhaust pipe clamp (1) to 30 Nm (22 lb ft).

11. Install the underbody rear air guide. Refer to Underbody Rear Air Deflector Replacement Service and Repair.

12. Lower and unsupport the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.