Exhaust System: Service and Repair

Replacing exhaust manifold
Slacken off front exhaust pipe





Remove nuts at flange joins at manifold.
Remove carriage bolts.

Remove the exhaust manifold





Remove two heat deflector plates from manifold.
Remove manifold from studs.
Turn manifold 90° to the right and lift up.
Check gasket face to cylinder head

Caution: Applies to cars with Air Conditioning (A/C): Do not damage the pressure switch (Pressostat) on the Air Conditioning (A/C) pipe.

Note! Studs should always be secured with strong thread seal, P/N 1161076-5, when installed.

Install exhaust manifold





Install manifold Use new gaskets.
Locate the front exhaust pipe to the manifold with carriage bolts.
Tighten manifold to cylinder head. Torque to 25 Nm.
Reinstall the heat deflector plates.
Tighten the front exhaust pipe to the manifold, Use copper paste on the copper bolts. The nuts should be tightened to the top of the thread. Do not tighten more than 10 Nm.

Note! Do not forget to install the springs and washers as well as the two exhaust pipe nuts.

Replacing exhaust pipe

Note! General Check rubber mountings, replace if necessary. The play between the exhaust system and bodywork should not be less than 20 mm.

Installing system assembly
To avoid tension in the system follow the following procedure:





1. Thread the silencer tail pipe between the floor and rear axle.
2. Then hang the silencer from the rubber mounts.
3. Install the Three-Way Catalytic Converter (TWC) and partially tighten the flanged joint to the exhaust manifold
4. Connect the exhaust system to the Three-Way Catalytic Converter (TWC), lubricate the terminal with copper paste (P/N 1 161 035-9). Align the other exhaust system components.
5. Tighten the Three-Way Catalytic Converter (TWC) to the exhaust pipe. Tighten the nuts to the top of the thread and then tighten to 10 Nm.
6. Tighten the front/rear pipe connections to 25 Nm.

Test function
Start engine.
Check for leaks.