Attention! Allow the exhaust system to cool before starting work. The catalytic converter, in particular, operates at very high temperatures. If it is not possible to cool the system, at least wear heat-protective gloves.
Withdrawal
1. Each section of the system can be removed individually. However, the entire system is not removed, as it passes over the rear beam.
2. To remove part of the system, raise the front of the vehicle and install safety stands. An alternative option may be to install the car on a flyover, viewing hole or lift.
Downpipe
(with catalytic converter on AHL petrol engines and all diesel engines)
Note: The flexible braided downpipe section must be handled with care and should not be excessively kinked.
3. Working under the vehicle, remove the floor cross member from the body.
4. Remove the air filter assembly as described in chapter 4A or 4B.
5. Turn away nuts and disconnect a reception pipe from a final collector (catalytic converter on AEB and AJL engines). Remove gasket (pic. 6.5, a, b).
6. Support the middle part (or short tube/catalytic converter) exhaust system with a rolling jack, unscrew the flange bolts and remove the exhaust pipe. Remove the gasket.
Catalytic converter (engines ADP, ADR, AFY)
7. Working under the vehicle, support the downpipe and center section with a safety support and ki and a rolling jack.
8. Turn away bolts of a flange and separate catalytic converter from a reception pipe. Remove the gasket.
9. Remember the clamp position (the bolts must be to the left of the clamp, the lower ends of the bolts must be below the intermediate pipe), unscrew the clamp bolts and disconnect the catalytic converter from the middle part (pic. 6.9).
Catalytic converter (engines AEB, AJL)
10. Remove the oxygen sensor paragraph 4 of chapter 4A.
11. Turn away bolts of fastening of a neutralizer to a reception pipe, remove a lining.
12. Remove the exhaust system bracket from the gearbox and lower the downpipe.
13. Turn away nuts of a flange and remove converter from the turbine. Remove the gasket. Remove the converter from under the car.
Short pipe (engines 1Z, AHU, ANN, AFN, AFF)
14. Turn away bolts of fastening of a flange and separate a reception pipe from catalytic converter.
15. Turn away bolts of a collar and separate a short pipe from an average part. Remove the short pipe from under the car.
Middle section and muffler
16. Working under the vehicle, support the downpipe with a rolling jack or stand.
17. If the original pipe is installed, it will be necessary to cut off the middle section to separate it from the rear section with silencer. The pipe has cut marks. Cut the pipe with a hacksaw or cut-off wheel at a right angle.
18. If the pipe has already been changed, unscrew the clamp bolts and separate the middle pipe from the rear.
19. Remember the position of the clamp securing the middle part to the converter (the bolts must be to the left of the clamp, the lower ends of the bolts must be below the pipe). Turn away bolts of a collar and separate converter.
20. Disconnect the rubber suspension and remove the middle part with the muffler from under the car.
Rear end with silencer
21. If the original pipe is installed, the middle part must be cut off to separate it from the rear part with the muffler. The pipe has cut marks. Cut the pipe with a hacksaw at a right angle.
22. If the pipe has already been changed, unscrew the clamp bolts and separate the middle pipe from the rear. Note the position of the clamp: the bolts must face the rear of the vehicle and the ends of the bolts must not protrude beyond the pipe.
23. Disconnect the rubber fasteners of the pipe and remove it from under the car (pic. 6.23, a, b).
Installation
24. Installation - reverse procedure. Pay attention to the following.
- A) Remove all traces of corrosion from the flange joints and install new gaskets.
- b) Damaged rubber mounts must be replaced.
- V) Before tightening the fastening clamps, make sure that the rubber fasteners are correctly installed, that there is sufficient clearance between the exhaust system and the body.
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