Removing
Raise the vehicle and place it on stands.
Lubricate all threaded connections with a rust remover and leave for a while.
Loosen the clamp at the rear (main) muffler.
Remove the main muffler from the rubber hangers and disconnect from the additional muffler.
Place wooden spacers under the exhaust system.
On vehicles with 2.0 liter engines with a catalytic converter: unscrew the lambda probe from the exhaust pipe with a wrench, having previously disconnected the connector.
Attention! Lambda probe and catalytic converter are shock sensitive. It is not recommended to hit them and drop them.
Loosen the bolts securing the intake pipe to the exhaust manifold (see fig.). Figure A shows the flange of a C16NZ motor and figure B shows an E16NZ motor.
On vehicles with 1.7 liter turbo diesel engines and 2.0 liter turbo petrol engines: Loosen the exhaust pipe-to-turbocharger bolts.
Unscrew, where necessary, the bolts securing the exhaust pipe to the body.
Remove the exhaust system mount in front of the additional muffler from the rubber pads and remove the muffler.
Installation
Install the downpipe of the new exhaust system, having previously cleaned the mating surfaces and laid new seals and damping gaskets. Do not tighten the mounting bolts yet.
To ensure the possibility of subsequent disassembly, it is recommended to cover the threaded connections with a special anti-stick paste before assembly.
Lift the exhaust system with the help of an assistant or place it on wooden shims.
Install additional muffler on rubber suspensions.
Lay a new gasket under the exhaust pipe flange and pre-fasten the pipe with new bolts, do not tighten them yet.
Tighten downpipe holder bolts if necessary.
Install the rear main muffler on the exhaust pipe, after installing the clamp.
Correct the position of the main muffler and install it on rubber suspensions.
Before tightening the bolts of the exhaust system, adjust the position of all its elements without distortions and deformations. Observe the necessary distance between the elements of the system and the car body and ensure a uniform load on the rubber suspensions.
Tighten the system mounting bolts to the following torques:
- downpipe with exhaust manifold - torque 25 Nm,
- downpipe with turbocharger in cars with a 2.0 l turbo-petrol engine - 12 Nm,
- downpipe with turbocharger in cars with turbodiesel engines of 1.7 l - 65 Nm,
- downpipe with support - 20 Nm,
- ball joint - 12 Nm,
- clamps - 25 Nm,
- exhaust manifold on vehicles with 16-valve engines - 20 Nm.
In vehicles with 2.0 liter engines with a catalytic converter: before screwing in the lambda probe, grease its thread with Opel N1948602 paste (05613905). Screw in lambda probe and tighten to 30 Nm. Connect the connector by leading the wire so that it does not come into contact with the exhaust system anywhere. Fix the wire with clamps.
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