Removing
6. Raise and place the car on stands, if equipped, remove the engine crankcase protection (see chapter 2). Apply a 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 with wire to the bottom of the car.
7. Loosen the clamp connection of the rear section (additional muffler) (see resist. illustration). Mark the position of the rear additional muffler relative to the exhaust pipe.
20.7. clamp connection (1) fastenings of the rear section of the exhaust system (on the example of the Z14XE engine) - arrows indicate damping holders: 2. Additional muffler
8. Release the additional silencer from the damping holders and disconnect it from the middle section of the exhaust system.
9. On petrol engines, disconnect the connector (see resist. illustration) wiring postcatalytic lambda probe.
20.9. Connector (3) wiring lambda probe (on the example of the Z14XE engine) - arrows indicate damping holders: 4. Downpipe
10. Loosen the nuts securing the downpipe 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 fastened with a clamp connection.
11. Remove the elements of the exhaust system from the damping holders and remove them, if necessary, use the help of an assistant.
Installation
12. To prevent «sticking» fasteners, it is recommended to lubricate all threaded connections with copper-containing grease during installation (e.g. 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 - if the vehicle has a high mileage, the holders must be replaced without fail.
13. If the sections of the exhaust system were divided, connect them and tighten the fastening clamps. Pay attention to the density of pairing sections - otherwise, when analyzing the composition of exhaust gases, an unreliable result may be obtained.
14. If the exhaust pipe was replaced on gasoline models, reinstall the lambda probe on a new section (see below).
15. Install the exhaust system with the help of an assistant in the holders, without fully tightening the fixing nuts, fix the exhaust pipe on the catalyst / turbocharger with a new seal. Pay attention to the correct installation of the gasket.
16. Establish the back muffler in holders and, without tightening fastening, connect with average section of system of release of the fulfilled gases.
17. Check that the exhaust system is installed in accordance with the profile of the bottom and that there is no bending stress on the exhaust pipes. At the same time, make sure that there is a 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 fasteners. Install crankcase protection (with appropriate equipment) and lower the car. Check the system for leaks (see above).
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