Contents: Removal ⬇ Installation ⬇
Removal
6. Raise and place the vehicle on stands; if equipped, remove the engine crankcase guard (see Chapter 2). Apply rust remover to all connections of the exhaust system, do not start removing the system immediately - let the rust dissolve. Tie the sections of the exhaust system to the bottom of the car with wire.
7. Loosen the clamp connection of the rear section (additional muffler) (see accompanying illustration). Mark the position of the rear additional muffler relative to the exhaust pipe.
20.7. Clamp connection (1) for fastening the rear section of the exhaust system (using the Z14XE engine as an example) - the arrows indicate the damping holders: 2. Additional muffler
8. Release the additional muffler from the damping holders and disconnect it from the middle section of the exhaust system.
9. On petrol engines, disconnect the connector (see accompanying illustration) post-catalytic lambda probe wiring.
20.9. Connector (3) of the lambda probe wiring (using the Z14XE engine as an example) - the arrows indicate the damping holders: 4. Intake pipe
10. Loosen the nuts securing the inlet pipe to the catalytic converter (on petrol models), or to the turbocharger (on diesel) and separate it together with the seal.
Note: On the Z13DT engine, the front section is secured using a clamp connection.
11. Remove the exhaust system components from the damper holders and remove them, using an assistant if necessary.
Installation
12. To prevent fasteners from "sticking", it is recommended to lubricate all threaded connections with copper-containing grease during installation (for example, Liqui Moly LM-508-ASC). Used clamps and nuts must be replaced with new ones. Check the rubber holders for porosity and damage, replace if necessary - with high mileage of the car, the holders must be replaced without fail.
13. If the exhaust system sections were separated, connect them and tighten the clamps. Pay attention to the tightness of the section connections, otherwise the exhaust gas analysis may yield an unreliable result.
14. If the inlet pipe was replaced on petrol models, reinstall the lambda probe on the new section (see below).
15. Install the exhaust system with the help of an assistant in the holders, without fully tightening the fastening nuts, fix the inlet pipe to the catalytic converter/turbocharger with a new seal. Pay attention to the correct installation of the gasket.
16. Install the rear muffler into the holders and, without tightening the fastener, connect it to the middle section of the exhaust system.
17. Check that the exhaust system is installed in accordance with the profile of the bottom and that there is no stress on the exhaust pipes due to bending. At the same time, make sure that there is sufficient distance between the exhaust system and the body everywhere, the holders with elastic rubber elements must be evenly loaded.
18. Tighten the exhaust system fastening elements. Install the crankcase guard (with appropriate equipment) and lower the vehicle. Check the system for leaks (see above).
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