Exhaust system - general information and component removal

Emission control and exhaust systems / Exhaust system - general information and component removal

General information
1 The exhaust system is made up of the downpipe, (with integral catalytic converter, where fitted), the intermediate pipe and the tail section which contains the rear silencer.

2 On all models, the system is suspended throughout its entire length by rubber mountings, which are secured to the underside of the vehicle by metal brackets.

Removal
3 Each exhaust section can be removed individually or, alternatively, the complete system can be removed as a unit.

4 To remove the system or part of the system, first jack up the front or rear of the car and support it on axle stands (see “Jacking and vehicle support”). Alternatively position the car over an inspection pit or on car ramps.

Downpipe
5 Place blocks of wood under the catalytic converter/front silencer to act as a support.

Where applicable, refer to Chapter 4A or B and remove the Lambda sensor from the exhaust pipe.

6 Slacken the clamp and separate the down pipe from the intermediate pipe.

7 Undo the nuts and separate the downpipe from the exhaust manifold. Recover the gasket.

Catalytic converter
8 Where fitted, the catalytic converter is integral with the down pipe.

Intermediate pipe
9 Slacken the clamping ring bolts and disengage the clamp from the intermediate pipe-to-tailpipe joint and the intermediate pipe-to-catalytic converter/front silencer joint.

10 Disengage the intermediate pipe from the tailpipe and the catalytic converter/front silencer and remove it from underneath the vehicle.

Tailpipe
11 Slacken the clamping ring bolts and disengage the tailpipe at the joint.

12 Unhook the tailpipe from its mounting rubbers and remove it from the vehicle.

Complete system
13 Disconnect the down pipe from the manifold as described earlier in this Section.

14 With the aid of an assistant, free the system from all its mounting rubbers and manoeuvre it out from underneath the vehicle.

Heatshields
15 The heatshields, where fitted, are secured to the underside of the body by a combination of nuts, bolts and clips. Each shield can be removed once the relevant exhaust section has been removed. Note that if the shield is being removed to gain access to a component located behind it, in some cases it may prove sufficient to remove the retaining nuts and/or bolts and simply lower the shield, removing the need to disturb the exhaust system.

Refitting
16 Each section is refitted by a reverse of the removal sequence, noting the following points.

a) Ensure that all traces of corrosion have been removed from the flanges and renew all necessary gaskets.

b) inspect the rubber mountings for signs of damage or deterioration and renew as necessary.

c) On joints which are secured by clamping rings, apply a smear of exhaust system jointing paste to the joint mating surfaces to ensure an air-tight seal. Tighten the clamping ring nuts evenly and progressively to the specified torque so that the clearance between the clamp halves is equal on either side.

d) Prior to tightening the exhaust system fastenets, ensure that all rubber mountings are correctly located and that there is adequate clearance between the exhaust system and vehicle underbody.