Replacing the main and additional mufflers (Opel Astra J)

In case of damage to the main or additional muffler, through corrosion or burnout, they are replaced as a whole, since the mufflers together with the pipes are non-separable units. However, separate parts of the exhaust system are available for sale (for example, a main or additional muffler). They can be replaced by cutting off the damaged part and installing a new one using special connecting clamps. The muffler pipes should be cut on their straight sections (depending on the size of the pipes of the new units).

To remove the main and additional mufflers as an assembly, do the following.



1. Remove the rear suspension beam (see Removal and installation the rear suspension beam).



2. Unscrew the two nuts securing the flange of the inlet pipe to the flange of the additional muffler and separate the flanges.

Note: Replace the flange sealing gasket each time the connection is disassembled.

3. Unscrew the mounting bolt…



4. …and remove the rear support of the main muffler from its bracket.



5. Remove the two main muffler suspension mounts (see Replacing the exhaust system suspension cushions) and remove the main and additional mufflers as a whole, moving them out from under the car to the rear.

6. Install new mufflers in the reverse order of removal. To make it easier to install the cushions on the muffler brackets and body, lubricate the cushions with a soap solution.