On new vehicles, the exhaust system consists of two parts. When repaired, it is replaced by a three-part system (for vehicles with V6 engine up to 8/94 and diesel engine - in four parts). With a standard exhaust system, the center muffler cannot be replaced separately; in the event of a repair, the pre-muffler and after-muffler must also be replaced. If only the downstream muffler needs to be replaced, the exhaust system is sawn apart.
Attention: When installing parts of the exhaust system, make sure that their connections are tight. Otherwise, when measuring the level of harmful emissions, incorrect results may be obtained.
All parts of the exhaust system are bolted together and can be replaced separately. Self-locking nuts and gaskets must be replaced with new ones after removal. When installing a new exhaust system, it is recommended that all rubber holders be updated as well.
Withdrawal
Raise the car on the goats.
Spray all bolts and nuts of the exhaust system with a rust remover. Leave the agent on the surfaces of the parts for some time to show its effect.
Vehicles with catalytic converter: Unplug electrical connector -C- for oxygen sensor at front wall. Remove heat shield -B-, unscrew sensor from exhaust pipe and carefully remove together with seal -D-.
Attention: Do not take the oxygen sensor by the sensing element.
Unfasten the ground jumper between the catalytic converter and the body.
If equipped, unscrew the fastening of the ground jumpers of the radio interference suppression system.
Model from 9/94: Unfasten the cross member under the gearbox/exhaust system.
Remove bolts -arrows- securing front exhaust pipe to exhaust manifold.
Detach exhaust system from retaining rubber tabs.
Note: Before removing, check the rubber loops for cracks. To do this, it is easy to press the exhaust system down and inspect the hinges, illuminating them with a flashlight. If necessary, replace the retaining rubber loops.
Attention: catalytic converter (built into the front exhaust pipe) very sensitive to shock, do not let it fall.
Installation
Before installing, clean the connecting flanges of the exhaust manifold and the front exhaust pipe with a steel brush. Be sure to use new seals and bolts, if necessary, also replace the retaining rubber loops. To make the exhaust system bolts easier to loosen later, it is recommended to lubricate them with a high temperature paste, such as Liqui Moly LM-508-ASC.
Vehicles with V6 engines up to 8/94: Separate both front exhaust pipes of the old exhaust system and transfer the mounting bracket to the new exhaust pipes.
Fit the front exhaust pipe with a new gasket to the exhaust manifold flange (for a turbocharged diesel engine - to the turbocharger flange) and tighten the mounting bolts to 50 Nm. If a leak was found in this place before removal, lay the sealing gasket very carefully and, when tightening the bolts, monitor its position.
Attention. Under no circumstances should any sealants be used, as this can damage the oxygen sensor and catalytic converter.
Insert the holder of the front muffler into the retaining loops and align the muffler. Insert new mounting bolts into the flanges at the front exhaust pipe and tighten slightly.
Vehicle with V6 engine up to 8/94
Apply a sealant, such as Gun Gum, to both connections between the front and downstream mufflers.
Connect the pre-silencer to both front exhaust pipes and. without tightening, install the fastening yoke.
Slide the retaining tabs onto the holders of the left pre-muffler. Insert the holders of the right pre-muffler into the retaining tabs and screw the holders of the left pre-muffler to the body.
Place the U-shaped yoke on the connecting tube of the downstream muffler and apply high-temperature paste to the junction of the intermediate pipe.
Slide the downstream muffler onto the intermediate pipe and insert the holder into the rubber loop.
Align exhaust system. The distance between the exhaust system and the bodywork and adjacent parts must be at least 25 mm. Retaining loops must be loaded evenly, without overtightening and distortion.
Tighten the U-bolt nuts and the tie bolts for the front exhaust pipe connection to 40 Nm.
If equipped, tighten the radio interference suppression system ground jumpers.
Vehicle with catalytic converter: Screw the oxygen sensor with a new seal into the exhaust pipe and tighten to 50 Nm. Pre-clean the thread and apply high-temperature paste to it Install the heat shield, connect the plug connector of the oxygen sensor. Tighten the ground strap between the catalytic converter and the body.
Model from 9/94: Tighten the 4 bolts for the cross member under the gearbox/exhaust system to 40 Nm.
Check the exhaust system for leaks.
Lower the car.
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